Polyisobutylene-based polyurethanes

ABSTRACT

An elastomeric polymer, comprising (1) a hard segment in the amount of 10% to 60% by weight of the elastomeric polymer, wherein the hard segment includes a urethane, urea or urethaneurea; and (2) a soft segment in the amount of 40% to 90% by weight of the elastomeric polymer. The soft segment comprises (a) at least 2% by weight of the soft segment of at least one polyether macrodiol, and/or at least one polycarbonate macrodiol; and (b) at least 2% by weight of the soft segment of at least one polyisobutylene macrodiol and/or diamine.

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 61/204,856, filed on Jan. 12, 2009, U.S. Provisional Application No. 61/211,310, filed on Mar. 26, 2009, and U.S. Provisional Application No. 61/279,629, filed on Oct. 23, 2009. The entire teachings of the above applications are incorporated herein by reference.

PARTIES TO A JOINT RESEARCH AGREEMENT

The claimed invention was made subject to a joint research agreement between Boston Scientific Corporation and the University of Massachusetts Lowell. Cardiac Pacemakers, Inc. is a wholly-owned subsidiary of Boston Scientific Corporation.

BACKGROUND OF THE INVENTION

Thermoplastic polyurethanes, polyureas and polyurethaneureas represent an important family of segmented block copolymer thermoplastic elastomers. They can be extruded, injection or compression molded or solution spun. They offer a broad range of physical properties and characteristics, including high tensile and tear strength, chemical and abrasion resistance, good processibility, and protective barrier properties. Depending on composition, i.e. on the volume fraction of the soft, elastomeric segments, these polymers can be soft, rubbery or hard and rigid materials. The hard segments of polyurethanes are composed of diisocyanate and a small molecule diol chain extender, while the soft segments are mostly low molecular weight polymeric diols. Similarly, polyureas or polyurethaneureas comprise diamines and a combination of diols and diamines, respectively, in addition to diisocyanate. Polymeric diols include polyester diols, polyether diols, and polydiene diols. The polyester component is prone to hydrolytic degradation, the polyether component does not have sufficient resistance to oxidative degradation, especially in vivo, and polydienes suffer from inadequate thermal and oxidative stability.

Polyurethanes are the most commonly used materials in the production of biomedical devices that come in contact with blood such as pacemakers, defibrillators, angioplasty balloons, surgical drains, dialysis devices, etc. However, polyurethanes generally exhibit insufficient long-term in vivo biostability due to oxidation of the polyether soft segment, especially when in contact with metals, which catalyze oxidative degradation. This deficiency, limits the use of polyurethanes for long-term applications.

Polyisobutylene (PIB)-based thermoplastic polyurethanes (TPUs) offer high thermal, oxidative, and hydrolytic stability, however, polyisobutylene polyurethanes exhibit insufficient mechanical properties.

SUMMARY OF THE INVENTION

It has now been discovered that incorporation of polyether diols into the PIB-based soft segments (e.g. 10-30% by weight of the soft segment) produces elastomeric polymer with significantly improved mechanical properties, processibility, and resistance to oxidative degradation.

In one embodiment, the present invention is an elastomeric polymer, comprising (1) a hard segment in the amount of 10% to 60% by weight of the elastomeric polymer, wherein the hard segment includes a urethane, urea or urethaneurea; and (2) a soft segment in the amount of 40% to 90% by weight of the elastomeric polymer. Preferably, the soft segment comprises (a) at least 2% by weight of the soft segment of at least one polyether macrodiol, and/or at least one polycarbonate macrodiol; and (b) at least 2% by weight of the soft segment of at least one polyisobutylene macrodiol or diamine. Preferably, the number average molecular weight of the elastomeric polymer is not less than about 40 kilodaltons. In other embodiments, the number average molecular weight of the elastomeric polymer is not less than about 50 kilodaltons.

In another embodiment, the present invention is an article of manufacture, comprising: an elastomeric polymer, said elastomeric polymer, including (1) a hard segment in the amount of 10% to 60% by weight of the elastomeric polymer, wherein the hard segment includes a urethane, urea or urethaneurea; and (2) a soft segment in the amount of 40% to 90% by weight of the elastomeric polymer. Preferably, the soft segment comprises (a) at least 2% by weight of the soft segment of at least one polyether macrodiol, and/or at least one polycarbonate macrodiol; and (b) at least 2% by weight of the soft segment of at least one polyisobutylene macrodiol or diamine. Preferably, the number average molecular weight of the elastomeric polymer is not less than about 40 kilodaltons. In other embodiments, the number average molecular weight of the elastomeric polymer is not less than about 50 kilodaltons.

In another embodiment, the present invention is a process for preparing an elastomeric polymer. The process comprises the steps of (a) forming a mixture that includes at least one polyisobutylene macrodiol, and/or diamine, at least one polyether macrodiol and a chain extender; and (b) reacting the mixture with a diisocyanate to yield a polyurethane elastomeric polymer. Preferably, the elastomeric polymer includes (i) a hard segment in the amount of 10% to 60% by weight of the elastomeric polymer, wherein the hard segment includes a urethane, urea or urethaneurea; and (ii) a soft segment in the amount of 40% to 90% by weight of the elastomeric polymer. Preferably, the soft segment includes at least 2% by weight of the soft segment of at least one polyether macrodiol, and/or at least one polycarbonate macrodiol, and at least 2% by weight of the soft segment of the at least one polyisobuylene macrodiol and/or diamine. Preferably, the number average molecular weight of the elastomeric polymer is not less than about 40 kilodaltons In other embodiments, the number average molecular weight of the elastomeric polymer is not less than about 50 kilodaltons.

In another embodiment, the present invention is a process for preparing a elastomeric polymer. The process comprises the steps of (a) reacting a diisocyanate with a mixture that includes at least one polyisobutylene macrodiol, and/or diamine, and at least one polyether macrodiol to form a prepolymer having terminally reactive diisocyanate groups; and (b) reacting the prepolymer with a chain extender to yield an elastomeric polymer. Preferably, the elastomeric polymer includes (i) a hard segment in the amount of 10% to 60% by weight of the elastomeric polymer, wherein the hard segment includes a urethane, urea or urethaneurea; and (ii) a soft segment in the amount of 40% to 90% by weight of the elastomeric polymer. Preferably, the soft segment includes at least 2% by weight of the soft segment of the at least one polyether macrodiol and/or at least one polycarbonate macrodiol, and at least 2% by weight of the soft segment of the at least one polyisobuylene macrodiol and/or diamine. Preferably, the number average molecular weight of the elastomeric polymer is not less than about 40 kilodaltons. In other embodiments, the number average molecular weight of the elastomeric polymer is not less than about 50 kilodaltons.

The polyisobutylene-based, polyether-containing thermoplastic polyurethanes of the present invention can be used to manufacture elastomeric materials useful in the production of biomedical devices such as pacemakers, defibrillators, angioplasty balloons, surgical drains, dialysis devices, etc. The elastomeric materials of the present invention possess a number of advantages over previously disclosed materials, including other polyisobutylene (PIB) based polyurethanes. Specifically, as described in the Exemplification section, adding a polyether (e.g. polytetramethyleneoxide diol, PTMO) to the PIB-based soft segment improves tensile strength and percent elongation. As demonstrated in Example 13, the PIB-based TPUs containing PTMO showed significant oxidative stability as compared to the commercial controls such as Pellethane™ 2686-55D and 2686-80A. After 12 weeks in vitro (equivalent of approximately 10 years in vivo) the PIB-PTMO TPUs with 10-20% PTMO in the soft segment showed 6-15% weight loss whereas the Pellethanes™ degraded completely in about 9 weeks. The weight loss was linearly proportional to the PTMO content in the PIB-PTMO TPUs.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing will be apparent from the following more particular description of example embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating embodiments of the present invention.

FIG. 1 is a schematic diagram of an example of a synthetic procedure employed to produce the polyisobutylene-containing thermoplastic polyurethanes that can be employed by the present invention.

FIG. 2 is a schematic diagram of an example of a synthetic procedure employed to produce the polyisobutylene/polyether-containing thermal polyurethanes of the present invention.

FIG. 3 is a bar plot showing the ultimate tensile strength (UTS) values of eight sample thermal polyurethane polymers of the present invention.

FIG. 4 is a bar plot showing the elongation at break values of eight sample thermal polyurethane polymers of the present invention.

FIG. 5 is a schematic diagram of an example of a synthetic procedure employed by the present invention to produce polyurethaneureas based on PIB and PTMO segment.

FIG. 6 is a representative FTIR spectrum of 60A 82 PIB-PTMO polyurethanes of the present invention.

FIG. 7 is a FTIR spectrum of Pellethane™ P55D.

FIG. 8 is a plot of the weight loss of various PIB-PTMO polyurethanes as a function of time of the present invention.

FIG. 9 is a plot of the weight loss of various PIB-PTMO polyurethanes of the present invention at 12 weeks as a function of PTMO content.

FIG. 10 is a plot of tensile strength of various PIB-PTMO polyurethanes of the present invention as a percentage of the original untreated sample as a function of time.

FIG. 11 is an a Gas Permeation Chromatography (GPC)/Refractive Index (RI) detection profile of a PIB-PTMO polyurethane sample of the present invention, “Sat 60A91”. The elution time is indicated in minutes.

FIG. 12 is a GPC/RI profile of Pellethane™ P80A shown for comparison with the profile of “Sat 60A91” of FIG. 11.

FIG. 13 depicts SEM pictures of Pellethane™ P55D taken at 300× magnification.

FIG. 14 depicts SEM pictures of PIB-PTMO polyurethane sample of the present invention, “80A 73” at 300× magnification.

FIG. 15 depicts SEM pictures of PIB-PTMO polyurethane sample of the present invention, “80A 82” at 300× magnification.

FIG. 16 depicts SEM pictures of PIB-PTMO polyurethane sample of the present invention, “80A 91” at 300× magnification.

DETAILED DESCRIPTION OF THE INVENTION

Glossary

As used herein, the term “polydispersity index” (PDI) means is a measure of the distribution of molecular mass in a given polymer sample. The PDI calculated is the weight average molecular weight divided by the number average molecular weight.

As used herein, the term “macrodiol” means a polymeric diol. Examples include polyether compounds of formula HO—[CH(R)—(CH₂)_(k)—O]_(l)—H,  (I) and polyisobutylene polymers of formula

Values and preferred values for the variables in formulas (I) and (II) are defined below.

Similarly, the phrase “macrodiol and/or diamine” is used, the reference is being made to a polymeric diamine similar in structure to the diols of formula (II), in which the terminal hydroxyl groups are replaced with amino or alkylaminogroups, as defined below.

As used herein, the term “telechelic”, when referring to a polymer, means a polymer carrying functionalized endgroups. Examples of telechelic polymers are difunctional polymers of formulas (I) and (II), above. Telechelic polymers can be used, e.g., for the synthesis of block co-polymers.

As used herein, the term “BDO” refers to 1,4-butanediol.

As used herein, the term “MDI” refers to 4,4′-methylenebis(phenylisocyanate).

As used herein, the term “PTMO” refers to polytetramethylene oxide.

As used herein, the term “PIB” means a polyisobutylene, i.e. a compound formed by polymerization of an optionally substituted butadiene.

As used herein, the term “TPU” means a thermoplastic polyurethane.

As used herein, the term “PIB-TPU” means a polyisobutylene-based thermoplastic polyurethane obtained by any known process. The term includes the elastomeric polyurethanes materials described herein.

As used herein, the term “PIB-PTMO-TPU” means a polyisobutylene-based, polytetramethylene oxide-containing thermoplastic polyurethane obtained by any known process and includes the elastomeric polyurethanes materials described herein.

As used herein, the term “initiator residue” refers to a difunctional chemical moiety, that links two linear chains of a polymer. For example, in a polyisobutylene polymer of formula

where values and preferred values for the variables are defined below, R₁ is an initiator residue. Examples of initiator residues include dicumyl and 5-tert-butyl-1,3 dicumyl that correspond to dicumyl chloride, methylether or ester, respectively, are used as initiator. Other examples include 2,4,4,6-tetramethylheptylene or 2,5-dimethylhexylene, which arise when 2,6-dichloro-2,4,4,6-tetramethylheptane or 2,5-dichloro-2,5-dimethylhexane is used as initiator. Many other cationic mono- and multifunctional initiators are known in the art. Definitions of Terms

The term “alkyl”, as used herein, unless otherwise indicated, means straight or branched saturated monovalent hydrocarbon radicals of formula C_(n)H₂₊₁. In some embodiments, n is from 1 to 18. In other embodiments, n is from 1 to 12. Preferably, n is from 1 to 6. In some embodiments, n is 1-1000, for example, n is 1-100. Alkyl can optionally be substituted with —OH, —SH, halogen, amino, cyano, nitro, a C1-C12 alkyl, C1-C12 haloalkyl, C1-C12 alkoxy, C1-C12 haloalkoxy or C1-C12 alkyl sulfanyl. In some embodiments, alkyl can optionally be substituted with one or more halogen, hydroxyl, C1-C12 alkyl, C2-C12 alkenyl or C2-C12 alkynyl group, C1-C12 alkoxy, or C1-C12 haloalkyl. The term alkyl can also refer to cycloalkyl.

The term “cycloalkyl”, as used herein, means saturated cyclic hydrocarbons, i.e. compounds where all ring atoms are carbons. In some embodiments, a cycloalkyl comprises from 3 to 18 carbons. Preferably, a cycloalkyl comprises from 3 to 6 carbons. Examples of cycloalkyl include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, and cycloheptyl. In some embodiments, cycloalkyl can optionally be substituted with one or more halogen, hydroxyl, C1-C12 alkyl, C2-C12 alkenyl or C2-C12 alkynyl group, C1-C12 alkoxy, or C1-C12 haloalkyl.

The term “haloalkyl”, as used herein, includes an alkyl substituted with one or more F, Cl, Br, or I, wherein alkyl is defined above.

The terms “alkoxy”, as used herein, means an “alkyl-O—” group, wherein alkyl is defined above. Examples of alkoxy group include methoxy or ethoxy groups.

The term “aryl”, as used herein, refers to a carbocyclic aromatic group. Preferably, an aryl comprises from 6 to 18 carbons. Examples of aryl groups include, but are not limited to phenyl and naphthyl. Examples of aryl groups include optionally substituted groups such as phenyl, biphenyl, naphthyl, phenanthryl, anthracenyl, pyrenyl, fluoranthyl or fluorenyl. An aryl can be optionally substituted. Examples of suitable substituents on an aryl include halogen, hydroxyl, C1-C12 alkyl, C2-C12 alkene or C2-C12 alkyne, C3-C12 cycloalkyl, C1-C12 haloalkyl, C1-C12 alkoxy, aryloxy, arylamino or aryl group.

The term “aryloxy”, as used herein, means an “aryl-O—” group, wherein aryl is defined above. Examples of an aryloxy group include phenoxy or naphthoxy groups.

The term arylamine, as used herein, means an “aryl-NH-”, an “aryl-N(alkyl)-”, or an “(aryl)₂-N-” groups, wherein aryl and alkyl are defined above.

The term “heteroaryl”, as used herein, refers to aromatic groups containing one or more heteroatoms (O, S, or N). A heteroaryl group can be monocyclic or polycyclic, e.g. a monocyclic heteroaryl ring fused to one or more carbocyclic aromatic groups or other monocyclic heteroaryl groups. The heteroaryl groups of this invention can also include ring systems substituted with one or more oxo moieties. Examples of heteroaryl groups include, but are not limited to, pyridinyl, pyridazinyl, imidazolyl, pyrimidinyl, pyrazolyl, triazolyl, pyrazinyl, quinolyl, isoquinolyl, tetrazolyl, furyl, thienyl, isoxazolyl, thiazolyl, oxazolyl, isothiazolyl, pyrrolyl, quinolinyl, isoquinolinyl, indolyl, benzimidazolyl, benzofuranyl, cinnolinyl, indazolyl, indolizinyl, phthalazinyl, pyridazinyl, triazinyl, isoindolyl, purinyl, oxadiazolyl, thiazolyl, thiadiazolyl, furazanyl, benzofurazanyl, benzothiophenyl, benzotriazolyl, benzothiazolyl, benzoxazolyl, quinazolinyl, quinoxalinyl, naphthyridinyl, dihydroquinolyl, tetrahydroquinolyl, dihydroisoquinolyl, tetrahydroisoquinolyl, benzofuryl, furopyridinyl, pyrolopyrimidinyl, and azaindolyl.

The foregoing heteroaryl groups may be C-attached or N-attached (where such is possible). For instance, a group derived from pyrrole may be pyrrol-1-yl (N-attached) or pyrrol-3-yl (C-attached).

Suitable substituents for heteroaryl are as defined above with respect to aryl group.

Suitable substituents for an alkyl, cycloalkyl include a halogen, an alkyl, an alkenyl, a cycloalkyl, a cycloalkenyl, an aryl, a heteroaryl, a haloalkyl, cyano, nitro, haloalkoxy.

Further examples of suitable substituents for a substitutable carbon atom in an aryl, a heteroaryl, alkyl or cycloalkyl include but are not limited to —OH, halogen (—F, —Cl, —Br, and —I), —R, —OR, —CH₂R, —CH₂OR, —CH₂CH₂OR. Each R is independently an alkyl group.

In some embodiments, suitable substituents for a substitutable carbon atom in an aryl, a heteroaryl or an aryl portion of an arylalkenyl include halogen, hydroxyl, C1-C12 alkyl, C2-C12 alkenyl or C2-C12 alkynyl group, C1-C12 alkoxy, aryloxy group, arylamino group and C1-C12 haloalkyl.

In addition, the above-mentioned groups may also be substituted with ═O, ═S, ═N-alkyl.

In the context of the present invention, an amino group may be a primary (—NH₂), secondary (—NHR_(p)), or tertiary (—NR_(p)R_(q)), wherein R_(p) and R_(q) may be any of the alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkoxy, aryl, heteroaryl, and a bicyclic carbocyclic group. A (di)alkylamino group is an instance of an amino group substituted with one or two alkyls.

A trialkylamino group is a group N⁺(Rt)₃, wherein Rt is an alkyl, as defined above.

Polyurethanes and Polyureas

As used herein, a “polyurethane” is any polymer consisting of a chain of organic units joined by urethane (carbamate, —NH—COO—) links. Polyurethane polymers can be formed by reacting a molecules containing at least two isocyanate functional groups with another molecule containing at least two alcohol (hydroxyl) groups. By reacting an isocyanate group, —N═C═O, with a hydroxyl group, —OH, a urethane linkage is produced. A catalyst can be used. Similarly, in polyureas the links are urea groups (—NH—CO—NH—) that are obtained by reacting an isocyanate group with an amine group —NH₂.

For example, polyurethanes can be produced by the polyaddition reaction of a polyisocyanate with a polyalcohol (a polyol, an example of which is a macrodiol). The reaction mixture can include other additives. A polyisocyanate is a molecule with two or more isocyanate functional groups, R¹—(N═C═O)_(n≧2) and a polyol is a molecule with two or more hydroxyl functional groups, R²—(OH)_(n>2). R¹ and R² are each independently an aliphatic or an aromatic moiety. The reaction product is a polymer containing the urethane linkage, —R¹NHCOOR²—.

Polyisocyanate that contain two isocyanate groups are called diisocyanates. Isocyanates can be aromatic, such as diphenylmethane diisocyanate (MDI) or toluene diisocyanate (TDI); or aliphatic, such as hexamethylene diisocyanate (HDI) or isophorone diisocyanate (IPDI). An example of an isocyanate is polymeric diphenylmethane diisocyanate, which is a blend of molecules with two-, three-, and four- or more isocyanate groups, with an average functionality of 2.7.

Polyols that contain two hydroxyl groups are called macrodiols, those with three hydroxyl groups are called macrotriols. Examples of polyols include polycarbonate polyols, polycaprolactone polyols, polybutadiene polyols, and polysulfide polyols.

Additive such as catalysts, surfactants, blowing agents, cross linkers, flame retardants, light stabilizers, and fillers are used to control and modify the reaction process and performance characteristics of the polymer.

Examples of aromatic isocyanates are toluene diisocyanate (TDI) and diphenylmethane diisocyanate (MDI). TDI consists of a mixture of the 2,4- and 2,6-diisocyanatotoluene isomers. Another example of an aromatic isocyanate is TDI-80 (TD-80), consisting of 80% of the 2,4-isomer and 20% of the 2,6-isomer.

Examples of aliphatic (including cycloaliphatic) isocyanates are 1,6-hexamethylene diisocyanate (HDI), 1-isocyanato-3-isocyanatomethyl-3,5,5-trimethyl-cyclohexane (isophorone diisocyanate, IPDI), and 4,4′-diisocyanato dicyclohexylmethane (H₁₂MDI). Other aliphatic isocyanates include cyclohexane diisocyanate (CHDI), tetramethylxylene diisocyanate (TMXDI), and 1,3-bis(isocyanatomethyl)cyclohexane (H₆XDI).

Chain extenders (f=2) and cross linkers (f=3 or greater) are low molecular weight hydroxyl and amine terminated compounds that play an important role in the polymer morphology of polyurethane fibers, elastomers, adhesives, and certain integral skin and microcellular foams. Examples of chain extenders and cross linkers are ethylene glycol (EG), 1,4-butanediol (BDO), diethylene glycol (DEG), glycerine, and trimethylol propane (TMP).

The elastomeric properties of polyurethanes, polyureas and polyurethaneureas are derived from the phase separation of the “hard segment” and the “soft segment” domains of the polymer chain. For example, hard segments that comprise urethane units can serve as cross-links between the soft segments that comprise polyol (e.g., macrodiol) units (e.g., polyisobutane diols, polyether diols, and/or polyester diols). Without being limited to any particular theory, it is believed that the phase separation occurs because the mainly non-polar, low melting soft segments are incompatible with the polar, high melting hard segments. The polyol-containing soft segments are mobile and are normally present in coiled formation, while the isocyanate-containing hard segments (which can also include chain extenders) are stiff and immobile. Because the hard segments are covalently coupled to the soft segments, they inhibit plastic flow of the polymer chains, thus creating elastomeric resiliency. Upon mechanical deformation, a portion of the soft segments are stressed by uncoiling, and the hard segments become aligned in the stress direction. This reorientation of the hard segments and consequent powerful hydrogen bonding contributes to high tensile strength, elongation, and tear resistance values.

Although the synthesis of polyurethanes is usually presented as proceeding via formation of urethane (carbamate) linkages by the reaction of isocyanates and alocohols, this is an oversimplification. See, for example, G. ODIAN: PRINCIPLES OF POLYMERIZATION, FOURTH ED. Wiley Interscience, 2004. Accordingly, it is more convenient to define the polyurethane compositions via weight percent of the components rather than structurally.

Accordingly, in some embodiments, the present invention is an elastomeric polymer, comprising (1) a hard segment in the amount of 10% to 60% by weight of the elastomeric polymer, wherein the hard segment includes a urethane, urea or urethaneurea; and (2) a soft segment in the amount of 40% to 90% by weight of the elastomeric polymer. The soft segment comprises at least 2% by weight of the soft segment of at least one polyether macrodiol, and/or at least one polycarbonate macrodiol and at least 2% by weight of the soft segment of at least one polyisobutylene macrodiol and/or diamine.

In certain embodiments, the number average molecular weight of the elastomeric polymer is not less than about 40 kilodaltons (kDa). In other embodiments, the number average molecular weight of the elastomeric polymer is not less than about 50 kilodaltons. In alternative embodiments, wherein the number average molecular weight of the elastomeric polymer is not less than about 60 kDa, not less than about 70 kDa, not less than about 80 kDa, not less than about 90 kDa, not less than about 100 kDa, not less than about 110 kDa, not less than about 120 kDa, not less that about 130 kDa, not less than about 140 kDa or not less than about 150 kDa.

In certain embodiments, the hard segment can be present in the amount of 15, 20, 25, 30, 35, 40, 45, 50, or 55%.

In certain embodiments, soft segment is present in the amount of 45, 50, 55, 60, 65, 70, 75, 80, or 85%. Polyether and/or polycarbonate can be present in the amount of 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80 or 85%. Polyisobutylene can be present in the amount of 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80 or 85%.

One of ordinary skill can easily determine a suitable polyether macrodiol. Preferably, at least one polyether macrodiol is a compound of formula HO—[CH(R)—(CH₂)_(k)—O]_(l)—H, wherein R, for each occurrence, is independently a C1-C12 alkyl or —H; k is an integer not less than 1; and 1 is an integer not less than 1.

One of ordinary skill can easily determine a suitable polyisobutylene macrodiol or diamine. Preferably, at least one polyisobutylene macrodiol and/or diamine is of formula:

wherein each X is independently —OH, —NH₂ or —NHR₄, and wherein R₁ is an initiator residue (defined above). R₂, R₃ and R₄ is each independently a C1-C16 alkyl, a C3-C16 cycloalkyl, a C2-C16 alkenyl, a C3-C16 cycloalkenyl, a C2-C16 alkynyl, a C3-C16 cycloalkynyl, or a C6-C18 aryl, wherein, for each occurrence, R₂ or R₃ is, independently, optionally substituted with one or more groups selected from halo, cyano, nitro, dialkylamino, trialkylamino, C1-C16 alkoxy and C1-C16 haloalkyl. Integers n and m are each, independently, from 1 to 500.

Preferably, the polyisobutylene macrodiol or diamine is hydroxy or amino allyl telechelic polyisobutylene. In one embodiment, the molecular weight of at least one polyisobutylene macrodiol or diamine is about 400 Da to about 6000 Da. For example, polyisobutylene macrodiol or diamine is about 500, 1000, 2000, 3000, 4000, or 5000 Da. In certain embodiments, the molecular weight of at least one polyisobutylene macrodiol or diamine is about 1000 Da to about 3000 Da. For example, the molecular weight of at least one polyisobutylene macrodiol or diamine is about 1000, 1500, 2000, or 2500 Da.

In preferred embodiments, R₂ and R₃ is each independently a moiety selected from —CH₂—CH═CH—CH₂—, —CH₂—CH₂—CH₂—CH₂—, —CH₂—CH₂—CH₂—, and —CH₂—CH(CH₃)—CH₂—.

In one embodiment, the elastomeric polymer of the present invention comprises a soft segment that includes at least one polyether macrodiol and at least one polycarbonate macrodiol; and at least 2% by weight of the soft segment of the at least one polyisobutylene macrodiol, and/or diamine.

In another embodiment, the elastomeric polymer of the present invention comprises a soft segment that includes: (a) about 10% to about 90% by weight of the soft segment of the at least one polyisobutylene macrodiol, and/or diamine; and (b) either about 10% to about 90% by weight of the soft segment of the at least one polyether macrodiol, or about 10% to about 90% by weight of the soft segment of the at least one polycarbonate macrodiol, or about 10% to about 90% by weight of the soft segment of the at least one polyether macrodiol and the at least one polycarbonate macrodiol.

For example, the soft segment can include from about 10% to about 30% by weight of the soft segment of at least one polycarbonate macrodiol. For example, the soft segment can include at least one polycarbonate macrodiol in the amount of 15, 20 or 25%. Alternatively, the soft segment can include from about 10% to about 30% by weight of the soft segment of the at least one polyether macrodiol and the at least one polycarbonate macrodiol. For example, the soft segment can include at least one polyether macrodiol and the at least one polycarbonate macrodiol in the amount of 15, or 25%.

In one embodiment, the soft segment can include from about 10% to about 30% by weight of the soft segment of the at least one polyether macrodiol. For example, the soft segment can include at least one polyether macrodiol in the amount of 15, 20 or 25%.

In another embodiment, the soft segment includes from about 10% to about 90% by weight of the soft segment of the at least one polyisobutylene macrodiol, and/or diamine. For example, the soft segment can include at least one polyisobutylene macrodiol, and/or diamine in the amount of 20, 30, 40, 50, 60, 70 or 80%.

In a further embodiment, the soft segment can include from about 70% to about 90% by weight of the soft segment of the at least one polyisobutylene macrodiol, and/or diamine. For example, the soft segment can include at least one polyisobutylene macrodiol, and/or diamine in the amount of 70, 75, 80 or 85%.

Preferably, at least one polyether macrodiol includes at least one member selected form the group consisting of poly(ethylene oxide) diol, polypropylene oxide) diol, poly(trimethylene oxide) diol, poly(tetramethylene oxide) diol, poly(hexamethylene oxide) diol, poly(heptamethylene oxide) diol, poly(octamethylene oxide) diol and poly(decamethylene oxide) diol.

One of ordinary skill in the art will be able to easily determine a suitable polycarbonate macrodiol. Preferably, at least one polycarbonate macrodiol includes at least one member selected from the group consisting of a poly(alkylene carbonate) of a formula

where R₇ is a hydrogen, a C1-C12 straight or branched alkyl, or a C3-C12 cycloalkyl, q is an integer greater than 1 and p is an integer greater than 2. Preferably, R₇ is a hydrogen. Examples of poly(alkylene carbonate) include poly(tetramethylene carbonate) diol, poly(pentamethylene carbonate) diol, poly(hexamethylene carbonate) diol, or copolymers of thereof.

In certain embodiments, the elastomeric polymer of the present invention comprises a hard segment present in the amount of from about 30% to about 50% by weight of the elastomeric polymer. For example, the hard segment present in the amount of 35, 40, or 45%.

Examples of the hard segments include the hard segments formed by reacting a diisocyanate with a chain extender. One of ordinary skill in the art will easily determine a suitable diisocyanate or a chain extender. The diisocyanate can be at least one member selected from the group consisting of 4,4′-methylenephenyl diisocyanate; methylene diisocyanate; p-phenylene diisocyanate; cis-cyclohexane-1,4-diisocyanate; trans-cyclohexane-1,4-diisocyanate; a mixture of cis cis-cyclohexane-1,4-diisocyanate and trans-cyclohexane-1,4-diisocyanate; 1,6-hexamethylene diisocyanate; 2,4-toluene diisocyanate; cis-2,4-toluene diisocyanate; trans-2,4-toluene diisocyanate; a mixture of cis-2,4-toluene diisocyanate and trans-2,4-toluene diisocyanate; p-tetramethylxylene diisocyanate; and m-tetramethylxylene diisocyanate. The chain extender can be at least one member selected from the group consisting of 1,4-butanediol; 1,5 pentanediol; 1,6-hexanediol; 1,8-octanediol; 1,9-nonanediol; 1,10-decanediol, 1,12-dodacanediol; 1,4-cyclohexane dimethanol; p-xyleneglycol and 1,4-bis(2-hydroxyethoxy)benzene. Preferably, the diisocyanate is 4,4′-methylenephenyl diisocyanate and the chain extender is 1,4-butanediol.

In a preferred embodiment, the polyurethane elastomeric polymer of the present invention comprises the soft segment formed from a hydroxyallyl telechelic polyisobutylene and poly(tetramethylene oxide) diol and the hard segment formed from 4,4′-methylenediphenyl diisocyanate and 1,4-butanediol.

In another preferred embodiment, the polyurethane elastomeric polymer of the present invention comprises the soft segment is derived from a hydroxyallyl telechelic polyisobutylene and poly(hexamethylene oxide) diol and the hard segment is derived from 4,4′-methylenediphenyl diisocyanate and 1,4-butanediol.

In another preferred embodiment, the polyurethane elastomeric polymer of the present invention comprises the soft segment formed from (a) a hydroxyallyl difunctional polyisobutylene and (b) poly(tetramethylene oxide) diol or poly(hexamethylene oxide) diol; and the hard segment formed from (c) 4,4′-methylenediphenyl diisocyanate and (d) 1,4-butanediol.

In certain embodiments, the present invention is an article of manufacture comprising any of the polyurethane elastomeric polymers described above. In preferred embodiments, the article is a medical device or an implant. Examples of the article of the present invention include a cardiac pacemaker, a defibrillator, a catheter, an implantable prosthesis, a cardiac assist device, an artificial organ, a pacemaker lead, a defibrillator lead, a blood pump, a balloon pump, an a-V shunt, a biosensor, a membrane for cell encapsulation, a drug delivery device, a wound dressing, an artificial joint, an orthopedic implant or a soft tissue replacement. In other embodiments, the article is a fiber, film, engineering plastic, fabric, coating, and adhesive joint.

The methods of synthesis of polyurethane compositions are generally well known by one of ordinary skill in the art of polymer chemistry. See, for example, Gunter Oertel, “Polyurethane Handbook”, 2nd ed. Hanser Publishers (1993); or Malcolm P. Stevens, “Polymer Chemistry”, 3d ed. Oxford University Press (1999). The relevant portions of these publications are incorporated herein by reference.

The present invention is based, in part, on the discovery of new and improved methods of polyurethane synthesis. Accordingly, in some embodiments, the present invention is a process for preparing a polyurethane elastomeric polymer. (See FIG. 2 for an example of such a procedure.) Generally, the process comprises the steps of (a) forming a mixture that includes at least one polyisobutylene macrodiol, and/or diamine, at least one polyether macrodiol and a chain extender; and (b) reacting the mixture with a diisocyanate to yield a polyurethane elastomeric polymer. Preferably, the elastomeric polymer includes (i) a hard segment in the amount of 10% to 60% by weight of the elastomeric polymer, wherein the hard segment includes a urethane, urea or urethaneurea; and (ii) a soft segment in the amount of 40% to 90% by weight of the elastomeric polymer. Preferably, the soft segment includes at least 2% by weight of the soft segment of at least one polyether macrodiol, and/or at least one polycarbonate macrodiol, and at least 2% by weight of the soft segment of the at least one polyisobuylene macrodiol, and/or diamine.

Any one or more of the isocyanates, polyols, chain extenders, or various additives can be employed with the synthetic method of the present invention. For example, polyether macrodiols and/or polyisobutylene macrodiol, described above, as well as any mixture thereof, can be used in the above-described process. Any amounts of the components and their combinations described above can be used.

Preferably, in the processes of the present invention, the mixture is formed at a temperature of about 45° C. to about 120° C. For example, the mixture is formed at a temperature of about 50, 60, 70, 80, 90, 100 or 110° C.

In some embodiments, the mixture is formed in the presence of a catalyst, such as stannous octoate. Other catalysts are well known in the art and can be used by one of ordinary skill in the art.

In an alternative embodiments, the present invention is a process for preparing a elastomeric polymer, comprising the steps of (a) reacting a diisocyanate with a mixture that includes at least one polyisobutylene macrodiol, and/or diamine and at least one polyether macrodiol to form a prepolymer having terminally reactive diisocyanate groups; and (b) reacting the prepolymer with a chain extender to yield a polyurethane elastomeric polymer. Preferably, the elastomeric polymer includes (i) a hard segment in the amount of 10% to 60% by weight of the elastomeric polymer, wherein the hard segment includes a urethane, urea or urethaneurea; and (ii) a soft segment in the amount of 40% to 90% by weight of the elastomeric polymer. Preferably, the soft segment includes at least 2% by weight of the soft segment of the at least one polyether macrodiol and/or at least one polycarbonate macrodiol, and at least 2% by weight of the soft segment of the at least one polyisobutylene macrodiol, and/or diamine.

Any one or more of the isocyanates, polyols, chain extenders, or various additives can be employed with the synthetic method of the present invention. For example, polyether macrodiols and/or polyisobutylene macrodiol, described above, as well as any mixture thereof, can be used in the above-described process. Any amounts of the components and their combinations described above can be used.

For example, at least one polyether macrodiol employed by the above-described process is poly(ethylene oxide) diol, polypropylene oxide) diol, poly(trimethylene oxide) diol, poly(tetramethylene oxide) diol, poly(hexamethylene oxide) diol, poly(heptamethylene oxide) diol, poly(octamethylene oxide) diol or poly(decamethylene oxide) diol.

Preferably, at least one polycarbonate macrodiol employed by the above-described process is a poly(alkylene carbonate), as described above.

Examples of the chain extenders that can be employed in the above-described process are 1,4-butanediol; 1,5-pentanediol; 1,6-hexanediol; 1,8-octanediol; 1,9-nonanediol; 1,10-decanediol, 1,12-dodecanediol; 1,4-cyclohexane dimethanol; p-xyleneglycol and 1,4-bis(2-hydroxyethoxy)benzene. Other examples include diamine chain extenders

EXEMPLIFICATION

Materials

Sn(Oct)₂ (stannous octoate, Polyscience), 4,4′-methylenebis(phenyl-isocyanate) (MDI, Aldrich, 98%), toluene (Aldrich, 99%), chloroform (Aldrich, at least 99.8%), 1,4-butanediol (BDO, Aldrich, 99%), Phthalimide, potassium (Aldrich, 98%), LiBr (Lithium bromide ReagentPlus®, Aldrich, at least 99%), KOH (potassium hydroxide, Aldrich), Na₂SO₄ (sodium sulfate, Aldrich), Trifluoroacetic acid (TFA, Aldrich), Tetra-n-butylammonium bromide (TBAB, Alfa Aesar, at least 98%) and Poly(tetramethylene oxide) (PTMO, TERATHANE® 1000 polyether glycol, Aldrich) were used as received. Tetrahydrofuran (THF) or toluene were refluxed over sodium metal and benzophenone over night and distilled under nitrogen atmosphere prior to use. Hexanes were purified by refluxing over sulfuric acid for 24 hours. They were washed with aqueous solution of KOH three times followed by distilled water. Then they were stored over sodium sulfate over night at room temperature. Finally they were distilled over CaH₂ under nitrogen atmosphere before use.

Measurements

Molecular weights were measured with a Waters HPLC system equipped with a model 510 HPLC pump, model 410 differential refractometer, model 441 absorbance detector, on-line multiangle laser light scattering (MALLS) detector (MiniDawn, Wyatt Technology Inc.), Model 712 sample processor, and five Ultrastyragel GPC columns connected in the following series: 500, 10³, 10⁴, 10⁵, and 100A. THF:TBAB (98:2, wt %) was used as a carrier solvent with a flow rate of 1 mL/min. Static tensile properties (Young's modulus, ultimate tensile strength, referred herein as “UTS”, elongation) were measured at room temperature (25° C.) and atmospheric conditions with a 50 N load cell on an Instron Model 4400R at 50 mm/min extension rate. All tests were carried out according to ASTM D412. Samples were cut into dog-bone shape using an ASTM die. All samples were kept at room temperature and atmospheric conditions prior to testing. The polymers were compression molded at 160° C. for 10 min using 17000 psi.

Example 1 Preparation of Ho-allyl-Polyisobutylene(PIB)-allyl-OH

The synthesis of HO-Allyl-PIB-Allyl-OH was carried out by heating the THF solution of bromoallyl telechelic PIB with aqueous solution of KOH at 130° C. for 3 hours.

For example, Br-Allyl-PIB-Allyl-Br (M_(n)=2200, 50 g, 0.023 mol) was dissolved in dry THF (1 liter) and a solution of KOH (50 g, 0.9 mol) in distilled water (500 mL) was added to it. The mixture was heated for 3 hour at 130° C. in a reactor. The reaction was cooled to room temperature. The THF was evaporated using a rotary evaporator. Distilled methanol (500 mL) was added and the precipitate was allowed to settle down. The precipitate was further dissolved in hexanes (200 mL) and slowly added to methanol (600 mL). The sticky mass was allowed to settle down. The process was repeated two times and the purified polymer was finally dried under vacuum at room temperature for 24 hour. Yield: 99%, GPC-MALLS: M_(n)=2400, polydispersity index (PDI)=1.16.

Representative molecular weight data for the hydroxy telechelic PIBs are described in Table 1, below.

TABLE 1 Molecular weight data of the hydroxyallyl telechelic PIBs Polymer M_(n) (NMR) M_(n) (GPC) PDI 1 4200 4300 1.10 2 2200 2400 1.16 3 1500 1600 1.17

Example 2 Syntheses of Polyisobutylene-Based Thermoplastic Polyurethane (PIB-TPU)

As used in Example 2, the terms “one-step procedure” and “two-step procedure” refer to the synthetic scheme exemplified in FIG. 1.

The syntheses of polyurethanes (PUs) with the ratio of soft segment (SS) to hard segment (HS) 80:20 (wt:wt), i.e. PIB(4200)-TPU (Sample Code PIB-TPU-4321), PIB(2200)-TPU (Sample Code PIB-TPU-2211) and PIB(1500)-TPU (Sample Code PIB-TPU-1514) were carried out in toluene using MDI and BDO as the chain extender in presence of 1 mol % of stannous octoate (relative to MDI) at 80° C. The polymers were obtained by adding MDI as the last reagent (one-step procedure).

One-Step Procedure

For examples, the material PIB-TPU-2211 was synthesized as follows. HO-Allyl-PIB-Allyl-OH (M_(n)=2200, 5.2 g, 2.36 mmol) and BDO (212 mg, 2.36 mmol) were azeotropically distilled from dry toluene (10 mL). The mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to this mixture, followed by Sn(Oct)₂ (20 mg, 0.05 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (1.24 g, 4.96 mmol) was added to this mixture and the mixture was stirred vigorously for 6 hours. The mixture was cooled to room temperature, poured into a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours. Representative molar ratio of the reactants and Shore hardness of the TPUs are described in Table 2.

TABLE 2 Molar ratio of reactants and Shore hardness of PIB TPU Shore HO-Allyl-PIB- MDI/BDO/PIB Wt % hardness Code Allyl-OH (M_(n))¹ (molar ratio) SS:HS (A) PIB-TPU-4321 4200 3/2/1 81:19 60 PIB-TPU-2211 2200 2/1/1 79:21 59 PIB-TPU-1514 1500 5/1/4 80:20 62 ¹M_(n) of precursor HO-Allyl-PIB-Allyl-OH

The M_(n) of PIB-TPU-2211 after various polymerization times is noted in Table 3. The increase in M_(n) was observed till 6 hour time. The polyurethane was then cured for one week at room temperature. A further increase in M_(n)=105000, PDI=2.4 was observed for the cured sample.

TABLE 3 Polymerization time and corresponding M_(n) data Polymerization time (h) M_(n) (GPC) PDI (GPC)  0¹ 2200 1.16   0.5 23000 1.8   0.7 32000 1.8 3 66000 2.0 6 87000 2.2 168  105000 2.4 ¹M_(n) of precursor HO-Allyl-PIB-Allyl-OH

The M_(n) of PIB-TPUs having Shore hardness of about 60A hardness prepared with polyisobutylenes having different molecular weights are summarized in Table 4. PIB-TPU-1514 was not soluble in THF:TBAB (98:2 wt %), hence the M_(n) could not be determined.

TABLE 4 GPC data of PIB-TPUs (Shore hardness 60A) Code M_(n) (GPC) PDI (GPC) PIB-TPU-4321 110000 2.3 PIB-TPU-2211  92000 3.1 PIB-TPU-1321 — —

The syntheses of polyurethanes with soft segment (SS) to hard segment (HS) ratio of 60:40 (wt %), e.g. PIB(4200)-TPU (Sample Code PIB-TPU-4761), PIB(2200)-TPU (Sample Code PIB-TPU-2431) and PIB(1500)-TPU (Sample Code PIB-TPU-1321) were carried out by a one-step synthetic procedure (see FIG. 1) in toluene using MDI and BDO as the chain extender and 1 mol % of stannous octoate (relative to MDI) as catalyst at 80° C.

For example, PIB-TPU-2431 was synthesized as follows. HO-Allyl-PIB-Allyl-OH (M_(n)=2200, 5.2 g, 2.36 mmol) and BDO (637 mg, 7.08 mmol) were azeotropically distilled from dry toluene (10 mL). The mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to this mixture, followed by Sn(Oct)₂ (38 mg, 0.09 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (2.36 g, 9.44 mmol) was added to the mixture and the mixture was stirred vigorously for 6 hours. The mixture was cooled to room temperature, poured in a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours.

Representative molar ratio of the reactants and Shore hardness of the TPUs are described in Table 5, below.

TABLE 5 Molar ratio of reactants and Shore hardness of PIB TPU Shore HO-Allyl-PIB- MDI/BDO/PIB Wt % hardness Code Allyl-OH (M_(n)) (molar ratio) SS:HS (A) PIB-TPU-4761 4200 7/6/1 62:38 81 PIB-TPU-2431 2200 4/3/1 60:40 79 PIB-TPU-1321 1500 3/2/1 59:41 83 The GPC analysis of the TPUs were carried out in THF:TBAB (98:2 wt %). The molecular weight values (Table 6) were obtained in the range of 83000-91000 with PDI in the range of 1.8-2.2.

TABLE 6 GPC data of PIB-TPUs (Shore hardness 80A) Code M_(n) (GPC) PDI (GPC) PIB-TPU-4761 87000 2.0 PIB-TPU-2431 91000 2.2 PIB-TPU-1321 83000 1.8

Representative mechanical property data of the PIB-TPUs are listed in Table 7. The UTS was obtained in the range of 6-9 MPa with elongation at break in the range of 40-400%. With an increase in the hard segment to soft segment ratio, the Young's modulus increased and the elongation at break decreased. The thermal processing of TPUs with higher Shore hardness was difficult compared to the softer ones. PIB-TPU-2431 and PIB-TPU-1321 could not be molded into flat sheets for testing, so the tensile properties were not recorded.

TABLE 7 Mechanical property data of PIB-TPUs Young's Tensile Elongation Polymer Shore (A) Modulus (MPa) Strength (MPa) (%) PIB-TPU-4321 60 6 7 200-250 PIB-TPU-4761 81 40  6 30-40 PIB-TPU-2211 59 5 9 300-400 PIB-TPU-2431 — — — — PIB-TPU-1514 62 5 6 100-150 PIB-TPU-1321 — — — —

Changing the catalyst of polymerization from tin octoate to 1,3-Diacetoxy-1,1,3,3-tetrabutyldistannoxane (DTDS) the UTS of PIB-TPU-2211 increased from 9 MPa to 12 MPa and the elongation at break decreased to 100% from 350% as shown in Table 8.

TABLE 8 Mechanical property data of the PIB TPUs Young's Tensile Elongation Polymer Shore A Modulus (MPa) Strength (MPa) (%) PIB-TPU-2211 59  5  9 300-400 Sn(Oct)₂ PIB-TPU-2211^(†) 60 24 12 100 DTDS PIB-TPU-2431 — — — — Sn(Oct)₂ PIB-TPU-2431^(†) 80 72 15 30-40 DTDS ^(†)not soluble in THF/TBAB, soluble in chloroform/TFA Two-Step Synthesis

In subsequent experiments, the technique for the polyurethane synthesis was modified by adding 1,4-butanediol (BDO) as the last reagent. The process consisted of two steps. (See FIG. 1.) In the first step, HO-Allyl-PIB-Allyl-OH was mixed with excess of MDI to form the intermediate PUs. In the subsequent step these intermediate polyurethanes were chain-extended with 1,4-butanediol to obtain the high molecular weight TPUs. A representative procedure is given below.

The PIB-TPU-4321 was synthesized using the two-step procedure by adding BDO last. HO-Allyl-PIB-Allyl-OH (M_(n)=4200, 5.2 g, 1.24 mmol) was azeotropically distilled from dry toluene (10 mL). The polymer was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to this mixture, followed by Sn(Oct)₂ (15 mg, 0.037 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. To it MDI (930 mg, 3.72 mmol) was added and the mixture was stirred vigorously for 30 min. BDO (223 mg, 2.48 mmol) was added to this mixture and stirring continued for 4 hours. The mixture was cooled to room temperature, poured in a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours.

As can be seen in Table 9, a higher molecular weight with narrow molecular weight distribution was observed for the polymer obtained by two-step synthesis compared to the polymer synthesized by one-step procedure. The tensile properties were similar in both the cases. The processing was easier, compared to the same TPU synthesized by the one-step procedure.

TABLE 9 M_(n) and tensile property data of PIB-TPU-4321 synthesized under different conditions Elongation at Procedure M_(n) (GPC) PDI (GPC) UTS (MPa) break (%) One-step 110000 2.3 7 200 Two-step 119000 1.6 7 150

Example 3 Synthesis of Polyisobutylene/Polyether-Based Thermoplastic Urethane (PIB-PTMO-TPU)

TPUs having mixtures of PIB and PTMO in different proportions as soft segment were synthesized using the two-step procedure according to the synthetic procedure exemplified in FIG. 2. BDO and MDI constituted the hard segment. The soft segment to hard segment ratio of 80:20 wt % was maintained in all the cases.

For example, PIB-PTMO-82-6 was synthesized as follows. HO-Allyl-PIB-Allyl-OH (M_(n)=2200, 5.2 g, 2.36 mmol) and PTMO (M_(n)=1000, 1.3 g, 1.3 mmol) were azeotropically distilled from dry toluene (10 mL). The mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to this mixture, followed by Sn(Oct)₂ (28.3 mg, 0.07 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (1.76 g, 7.02 mmol) was added to this mixture and the mixture was stirred vigorously for 30 min. BDO (302 mg, 3.36 mmol) was added to the resulting reaction mixture and the mixture was stirred for 4 hours at 100° C. The mixture was cooled to room temperature, poured in a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours.

The sample codes and weight percent values of PIB and PTMO is shown in Table 10.

TABLE 10 Weight Percent Values of PIB and PTMO in PIB-PTMO TPU (Shore hardness 60A) HO-PIB-OH¹ HO-PTMO-OH² Code (wt %)³ (wt %)³ PIB-PTMO-91-6 90 10 PIB-PTMO-82-6 80 20 PIB-PTMO-73-6 70 30 PIB-PTMO-64-6 60 40 PIB-PTMO-55-6 50 50 PIB-PTMO-28-6 20 80 PTMO-60A 0 100 ¹HO-PIB-OH, M_(n) = 2200, ²HO-PTMO-OH, M_(n) = 1000, ³soft:hard = 79:21 wt %

GPC-RI traces of the TPUs showed monomodal distribution of molecular weight with the values of molecular weight in the range of 55000-140000 and PDI of approximately 1.4-2.7. The molecular weight data of the TPUs synthesized according to the method described above are described in Table 11:

TABLE 11 Molecular weight data of PIB-PTMO TPU (Shore hardness ≈ 60A) Code M_(n) (GPC) PDI PIB-PTMO-91-6 94000 2.1 PIB-PTMO-82-6 129000 2.2 PIB-PTMO-73-6 137000 2.7 PIB-PTMO-64-6 95000 2.2 PIB-PTMO-55-6 85000 1.4 PIB-PTMO-28-6 55000 1.6 PTMO-60A 33000 1.3

The ultimate tensile strength (UTS) of the PIB-PTMO TPUs was approximately 4-20 MPa with elongation at break in the range of 400-740%. The Young's moduli of the polymers were obtained in the range of 2-9 MPa. The Shore hardness and tensile property data of the TPUs are listed in Table 12 below:

TABLE 12 Shore hardness and tensile property data of PIB-PTMO TPU Young's Tensile PTMO Modulus Strength Elongation Polymer (wt %) Shore A (MPa) (MPa) (%) PIB-PTMO-91-6 10 71 8.5 20 400 PIB-PTMO-82-6 20 60 5.2 18 680 PIB-PTMO-73-6 30 61 4.5 18 740 PIB-PTMO-64-6 40 59 4.7 22 740 PIB-PTMO-55-6 50 62 7.5 22 730 PIB-PTMO-28-6 80 61 2 4 400 PTMO-60A 100 60 5 10 500

With addition of a small amount of polytetramethyleneoxide diol (PTMO), the mechanical properties of the polymers increased dramatically. However, the properties remained similar with further increase in PTMO composition. TPU with 100% PTMO (PTMO-60A) also exhibited similar tensile property.

PIB-PTMO TPUs with higher hard segment to soft segment ratio were synthesized using the two-step procedure described above. The soft segment to hard segment ratio (SS:HS) of 65:35 percent by weight was maintained in all the cases, while the PIB to PTMO ratio (in percent by weight of the soft segment) was varied. Results are presented in Table 13.

TABLE 13 Percent Weight of PIB and PTMO in PIB-PTMO TPU (Shore hardness 80A) HO-PIB-OH¹ HO-PTMO-OH² Code (wt %)³ (wt %)³ PIB-PTMO-91-8 90 10 PIB-PTMO-82-8 80 20 PIB-PTMO-73-8 70 30 PIB-PTMO-64-8 60 40 PIB-PTMO-28-8 20 80 PTMO-80A 0 100 ¹HO-PIB-OH, M_(n) = 2200, ²HO-PTMO-OH, M_(n) = 1000, ³SS:HS = 65:35 wt %

Exemplary Synthesis of a PIB-PTMO-TPU

PIB-PTMO-82-8 was synthesized as follows. HO-Allyl-PIB-Allyl-OH M_(n)=2200, 5.2 g, 2.36 mmol) and PTMO (M_(n)=1000, 1.3 g, 1.3 mmol) were azeotropically distilled from dry toluene (10 mL). The mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to this mixture, followed by Sn(Oct)₂ (42 mg, 0.104 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (2.6 g, 10.38 mmol) was added to the reaction mixture, and the mixture was stirred vigorously for 30 min. BDO (605 mg, 6.72 mmol) was added to the reaction mixture, and the mixture was stirred for 4 hours at 100° C. The mixture was cooled to room temperature, poured in a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours.

Molecular weight data of PIB-PTMO TPUs with Shore hardness of 80A is shown in Table 14. The molecular weight of the polymers is in the range of 42000-138000, with PDI of 1.9-3.8.

TABLE 14 Molecular weight data of PIB-PTMO TPU (Shore hardness 80A) Code M_(n) (GPC) PDI PIB-PTMO-91-8 84000 1.9 PIB-PTMO-82-8 119000 2.8 PIB-PTMO-73-8 138000 3.5 PIB-PTMO-64-8 130000 3.7 PIB-PTMO-28-8 40000 3.8 PTMO-80A 42000 2.4

The ultimate tensile strength (UTS) of the PIB-PTMO TPUs (Shore hardness 80A) were in the range of 18-25 MPa with elongation at break in the range of 150-550%. The Young's modulus of the polymers were higher compared to PIB-PTMO TPUs with lower Shore hardness (60A) and varied between 11-32 MPa. Increase in PTMO concentration linearly increased the UTS as well as the elongation at break of the TPUs. The PIB-PTMO TPU comprising PTMO-80A exhibited highest UTS and elongation at break. The Shore hardness and tensile property data of the TPUs are listed in Table 15 below.

TABLE 15 Shore hardness and tensile property data of PIB-PTMO TPU (Shore hardness 80A) Young's Tensile Tear Modulus Strength Elongation Strength Polymer Shore A (MPa) (MPa) (%) (pli) PIB-PTMO-91-8 83 32 18 150 310 PIB-PTMO-82-8 82 32 23 400 380 PIB-PTMO-73-8 81 23 27 370 409 PIB-PTMO-64-8 81 11 25 550 440 PIB-PTMO-28-8 81 5 8 550 270

Exemplary Synthesis of the PIB-PTMO TPU Performed at 120° C.

PIB-PTMO TPUs having not less than 80 percent by weight of the soft segment of the PTMO component were synthesized according to the synthetic scheme exemplified in FIG. 2. The soft segment to hard segment ratio (SS:HS) was varied to achieve Shore hardness values of 60A to 80A.

For example, PIB-PTMO-28-8 was synthesized as follows. HO-Allyl-PIB-Allyl-OH (M_(n)=2200, 1.12 g, 0.51 mmol) and PTMO (M_(n)=1000, 4.48 g, 4.48 mmol) were azeotropically distilled from dry toluene (10 mL). The mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to the reaction mixture, followed by Sn(Oct)₂ (44.6 mg, 0.11 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (2.67 g, 10.7 mmol) was added to the reaction mixture, and the mixture was stirred vigorously for 30 min. BDO (520 mg, 5.7 mmol) was added to the reaction mixture, and the temperature was raised to 120° C. After 15 minutes, the temperature was decreased to 100° C. and the mixture was kept under nitrogen for 4 hours. The mixture was cooled to room temperature, poured in a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours.

The GPC data of the TPUs having PTMO in excess of 80% by weight of the soft segment is given in Table 16 below. The molecular weight values of these TPUs increased compared to the polymers that were synthesized from the same starting materials, but at a temperature of 100° C. (Table 11 and 14).

TABLE 16 Molecular Weight Data of PIB-PTMO TPU, Soft Segment Including not Less than 80% by Weight of PTMO (Reaction Temperature = 120° C.) Code M_(n) (GPC) PDI PIB-PTMO-28-6 105000 2.3 PTMO-60A 113000 2.0 PIB-PTMO-28-8 87000 1.8 PTMO-80A 102000 1.7

The UTS, ultimate elongation at break and Young's modulus data of the TPUs of Table 16 are listed in Table 17 below. The UTS of PTMO-60A (compare to Table 12) increased from 10 MPa to 20 MPa when the synthetic procedure was modified by increasing the reaction temperature to 120° C. A 200% enhancement in ultimate elongation at break was also observed. Other TPUs also exhibited improved tensile properties, as shown in Table 17. The tensile data of the PIB-PTMO-28-6 (see Table 12) and PIB-PTMO-28-8 (see Table 15) synthesized at 100° C. are described previously.

TABLE 17 The Tensile Property of PIB-PTMO TPU, Soft Segment Including not Less than 80% by Weight of PTMO (Reaction Temperature = 120° C.) Young's UTS Elongation Modulus Code Shore A (MPa) at break (%) (MPa) PIB-PTMO-28-6 60 22 950 7 PTMO-60A 60 20 700 5 PIB-PTMO-28-8 81 17 740 9 PTMO-80A 80 35 800 7

Synthesis of PIB-PTMO-TPU (Shore Hardness About 95A)

PIB-PTMO TPUs with designed Shore hardness of about 95A were synthesized using the two-step procedure described above. The soft segment to hard segment ratio (SS:HS) of 60:40 w:w was maintained in all the cases, while the PIB to PTMO weight ratio was varied as shown in Table 18.

TABLE 18 Percent Weight of PIB and PTMO in PIB-PTMO TPU (Shore hardness 95A) HO-PIB-OH¹ HO-PTMO-OH² Code (wt %)³ (wt %)³ PIB-PTMO-91-9 90 10 PIB-PTMO-82-9 80 20 PIB-PTMO-73-9 70 30 PIB-PTMO-64-9 60 40 PIB-PTMO-55-9 50 50 ¹HO-PIB-OH, M_(n) = 2200, ²HO-PTMO-OH, M_(n) = 1000, ³SS:HS = 60:40 wt %

For example, PIB-PTMO-73-9 was synthesized as follows. HO-Allyl-PIB-Allyl-OH (M_(n)=2200, 3.92 g, 1.78 mmol) and PTMO (M_(n)=1000, 1.68 g, 1.68 mmol) were azeotropically distilled from dry toluene (10 mL). The mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to the reaction mixture, followed by Sn(Oct)₂ (49 mg, 0.121 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (3.03 g, 12.12 mmol) was added to the reaction mixture, and the mixture was stirred vigorously for 30 min. BDO (780 mg, 8.66 mmol) was added to the reaction mixture, and the mixture was stirred for 4 hours at 100° C. The mixture was cooled to room temperature, poured in a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally, the polymer was dried under vacuum at 50° C. for 12 hours.

The molecular weight data of PIB-PTMO TPUs with Shore 95A hardness shown in Table 19. The molecular weight of the polymers was in the range of 79000-111500, with PDI of 1.6-3.4.

TABLE 19 Molecular weight data of PIB-PTMO TPU (Shore hardness 95A) Code Mn (GPC) PDI (GPC) PIB-PTMO-91-9* — — PIB-PTMO-82-9 87000 3.4 PIB-PTMO-73-9 79000 1.6 PIB-PTMO-64-9 105000 2.5 PIB-PTMO-55-9 111500 2.8 *The TPU is sparingly soluble in THF/TBAB mixture

The UTS, Shore hardness, tear strength and Young's modulus data for PIB-PTMO-TPU (Shore hardness of about 95A) are presented in Table 20. The UTS and Young's modulus of the polymers were observed in the range of 14-42 MPa and 144-17 MPa respectively. The elongation at break was observed in the range of 30-510%. The UTS and Young's modulus of PIB-PTMO-73-9 was higher compared to the TPUs having same PIB/PTMO ratio of 70/30 by weight, such as PIB-PTMO-6 and PIB-PTMO-8 TPUs with Shore hardness 60A (PIB-PTMO-73-6) and 80A (PIB-PTMO-73-8).

TABLE 20 Tensile properties of PIB-PTMO-TPU (Shore hardness ≈ 95A) UTS Young's Elongation at Code Shore A (MPa) Modulus (MPa) break (%) PIB-PTMO-91-9 95 14 144 30 PIB-PTMO-82-9 98 29 50 310 PIB-PTMO-73-9 99 40 45 350 PIB-PTMO-64-9 98 39 27 430 PIB-PTMO-55-9 96 42 17 510

Example 4 Synthesis of Polyisobutylene/Poly(alkylenecarbonate)-Based Thermoplastic Urethane (PIB-PHMC-TPU)

TPU, having a mixture of PIB and poly(hexamethylene carbonate) (PHMC) in the ratio of 70:30 percent by weight of the soft segment was synthesized using the procedure similar to the one illustrated in FIG. 2. The hard segment comprised BDO and MDI. The ratio of hard segment to soft segment, HS:SS, was 21:79 percent by weight.

A synthetic procedure for PIB-PHMC-73-6 is given below. PIB-PHMC-73-6 was synthesized as follows. HO-Allyl-PIB-Allyl-OH (M_(n)=2200, 4.5 g, 2.04 mmol) and PHMC (M_(n)=860, 1.93 g, 2.27 mmol) were azeotropically distilled from dry toluene (10 mL). The reaction mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to the reaction mixture, followed by Sn(Oct)₂ (26.3 mg, 0.065 mmol) in toluene. The reaction mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (1.63 g, 6.51 mmol) was added to the reaction mixture and the mixture was stirred vigorously for 30 minutes. BDO (200 mg, 2.2 mmol) was added to the reaction mixture and the mixture was stirred for 4 hours at 100° C. The reaction mixture was cooled to room temperature, poured in a Teflon® mold, and the solvent was evaporated at room temperature in air for 48 hours. Finally, the polymer was dried under vacuum at 50° C. for 12 hours.

The ultimate tensile strength (UTS) of the PIB-PHMC-73-6 was 10 MPa with elongation at break of about 300%. The Young's modulus of the polymer was 10 MPa with Shore (A) hardness about 61 A.

Example 5 Preparation of an Elastomeric Polymer Comprising Polyisobutylene-diamine

The synthesis of H₂N-Allyl-PIB-Allyl-NH₂ was carried out by heating the THF:DMF (70:30, v:v) solution of chloroallyl telechelic PIB with phthalimide potassium under reflux conditions for 18 hours followed by hydrolysis in presence of NH₂NH₂.H₂O.

For example, Phthalimide-Allyl-PIB-Allyl-Phthalimide was synthesized as follows. Cl-Allyl-PIB-Allyl-Cl (M_(n)=2100, 10 g, 0.0048 mol) was dissolved in dry THF (300 mL) and dry DMF (100 mL) followed by the addition of phthalimide potassium (50 g, 0.27 mol) and the mixture was refluxed under dry nitrogen atmosphere for 18 h. The reaction mixture was cooled to room temperature, filtered and THF was evaporated. Methanol was added to the sticky mass left over and the precipitate was separated and dissolved in hexanes. The solution was reprecipitated in methanol. The product obtained was further purified by dissolution and reprecipitation using hexanes and methanol.

A typical synthetic procedure for H₂N-Allyl-PIB-Allyl-NH₂ is as follows. Phthalimide-Allyl-PIB-Allyl-Phthalimide (9 g, 0.0042 mol) was dissolved in THF (200 mL) and hydrazine hydrate (15 g) was added. The mixture was refluxed for 24 h. The reaction was stopped and cooled to room temperature. A solution of KOH (10 g, in 25 mL of water) was added and stirred for 30 min. THF was evaporated under reduced pressure and methanol was added. The precipitate obtained was purified by dissolving in hexanes and reprecipitating in methanol. Yield: 98%, NMR: M_(n)=2100.

Example 6 Synthesis of Polyisobutylene/Poly(tetramethylene Oxide)-Based Thermoplastic Urethaneurea (PIB-PTMO-TPUU)

A series of PIB based polyurethaneurea with designed Shore 80A hardness was synthesized by chain extension of H₂N-Allyl-PIB-Allyl-NH₂ and HO-PTMO-OH with BDO and MDI as exemplified in FIG. 3. The ratio of PIB:PTMO was varied and the SS:HS w:w ratio was maintained at 65:35 as shown in Table 21. The synthetic route is is schematically depicted in FIG. 5.

TABLE 21 Percent Weight of PIB and PTMO in PIB-PTMO TPUU (Shore hardness 80A) H₂N-PIB-NH₂ ¹ HO-PTMO-OH² PTMO Code (wt % in SS) (wt % in SS) (wt % in TPUU) PIB-TPUU-82-8 80 20 13 PIB-TPUU-73-8 70 30 19 PIB-TPUU-64-8 60 40 26 PIB-TPUU-19-8 10 90 59 ¹H₂N-PIB-NH₂ (M_(n)) = 2100, ²HO-PTMO-OH (M_(n)) = 1000

Exemplary Synthesis of a PIB-PTMO-TPUU

PIB-TPUU-82-8 was synthesized as follows. H₂N-Allyl-PIB-Allyl-NH₂ M_(n)=2100, 5.2 g, 2.36 mmol) and PTMO (M_(n)=1000, 1.3 g, 1.3 mmol) were azeotropically distilled from dry toluene (10 mL). The mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to this mixture, followed by Sn(Oct)₂ (42 mg, 0.104 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (2.6 g, 10.38 mmol) was added to the reaction mixture, and the mixture was stirred vigorously for 30 min. BDO (605 mg, 6.72 mmol) was added to the reaction mixture and the mixture was stirred for 4 hours at 100° C. The mixture was cooled to room temperature, poured in a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours.

Molecular weight data of PIB-PTMO TPUUs with Shore 80A hardness are shown in Table 22. The molecular weight of the polymers is in the range of 98700-119000, with PDI=1.6-2.8.

TABLE 22 Molecular weight data of PIB-PTMO TPUU (Shore hardness 80A) Code M_(n) (GPC) PDI (GPC) PIB-TPUU-82-8 104000 1.8 PIB-TPUU-73-8 98700 2.5 PIB-TPUU-64-8 106500 2.8 PIB-TPUU-19-8 119000 1.6

The UTS, Shore hardness, tear strength and Young's modulus data for PIB-PTMO-TPUU are presented in Table 23. The UTS of the polymers was observed in the range of 23-32 MPa and the Young's modulus varied between 5 to 50 MPa. The elongation at break was observed in the range of 250-675%.

TABLE 23 Tensile properties of PIB-PTMO-TPUU (Shore hardness ≈ 80A) UTS Young's Elongation at Code Shore A00 00(MPa) Modulus (MPa) break (%) PIB-TPUU-82-8 86 23 50 250 PIB-TPUU-73-8 85 26 30 310 PIB-TPUU-64-8 89 32 21 420 PIB-TPUU-19-8 86 29 5 675

Example 4 Mechanical Measurements of Selected Sample TPUs

Ultimate tensile strength (UTS) and elongation at break were measured as described above for eight samples:

A, PIB-TPU-2221 (shown in Table 7),

B, PIB-PTMO-91-6 (shown in Table 12),

C, PIB-PTMO-82-6 (shown in Table 12),

D, PIB-PTMO-73-6 (shown in Table 12),

E, PIB-PTMO-64-6 (shown in Table 12),

F, PIB-PTMO-55-6 (shown in Table 12),

G, PIB-PTMO-28-6 (shown in Table 12), and

H, PTMO-60A (shown in Table 17).

These samples were synthesized according to the procedure described in Example 3, above. The samples differed in the content of PTMO, a polyether diol.

The results are presented in FIG. 3 and FIG. 4. As can be seen, addition of PTMO improves the mechanical properties of a PIB-based TPU, compared with Sample A. Furthermore, comparison with Sample H, which does not contain any PIB shows that the TPUs based on a combination of the PIB macrodiols and polyether macrodiols possess mechanical properties that are superior to the TPUs based on PIB macrodiols or polyether macrodiol alone.

Example 7 Synthesis of Polyisobutylene/Polyether-Based Thermoplastic Urethane (PIB-PTMO-TPU, 50A Shore Hardness)

TPU having mixture of PIB and PTMO in 80:20 weight proportion as soft segment was synthesized using the two-step procedure according to the synthetic procedure exemplified in FIG. 2. BDO and MDI constituted the hard segment. The soft segment to hard segment ratio of 82:18 wt % was maintained.

For example, PIB-PTMO-82-5 was synthesized as follows. HO-Allyl-PIB-Allyl-OH (M_(n)=2250, 5.0 g, 2.2 mmol) and PTMO (M_(n)=1000, 1.25 g, 1.25 mmol) were dried by azeotropic distillation from dry toluene (10 mL) solution. The mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to this mixture, followed by Sn(Oct)₂ (20.3 mg, 0.05 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (1.32 g, 5.3 mmol) was added to this mixture and the mixture was stirred vigorously for 30 min. BDO (170 mg, 1.87 mmol) was added to the resulting reaction mixture and the mixture was stirred for 4 hours at 100° C. The mixture was cooled to room temperature, poured in a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours.

The TPU exhibited the following characteristics: M_(n)=75000, PDI=1.7, UTS=14 MPa and elongation at break=800%, Young's modulus=3 MPa, flexural modulus=11 MPa, tear strength=292 pli.

Example 8 Synthesis of Polyisobutylene/Polyether-Based Thermoplastic Urethane (PIB-PTMO-TPU, 55a Shore Hardness)

TPU having mixture of PIB and PTMO in 80:20 weight proportion as soft segment was synthesized using the two-step procedure according to the synthetic procedure exemplified in FIG. 2. BDO and MDI constituted the hard segment. The soft segment to hard segment ratio of 81:19 wt % was maintained.

For example, PIB-PTMO-82-5.5 was synthesized as follows. HO-Allyl-PIB-Allyl-OH (M_(n)=2250, 5.4 g, 2.4 mmol) and PTMO (M_(n)=1000, 1.35 g, 1.35 mmol) were dried by azeotropic distillation from dry toluene (10 mL) solution. The mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to this mixture, followed by Sn(Oct)₂ (25.9 mg, 0.06 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (1.55 g, 6.21 mmol) was added to this mixture and the mixture was stirred vigorously for 30 min. BDO (223 mg, 2.46 mmol) was added to the resulting reaction mixture and the mixture was stirred for 4 hours at 100° C. The mixture was cooled to room temperature, poured in a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours.

The TPU exhibited the following characteristics: M_(n)=105000, PDI=2.0, UTS=13 MPa, elongation at break=900%, Young's modulus=3.6 MPa, tear strength is 295 pli.

Example 9 Synthesis of (Saturated) Polyisobutylene/Polyether-Based Thermoplastic Urethane (PIB_(sat)-PTMO-TPU, 60A Shore Hardness)

TPU having mixtures of hydroxypropyl telechelic PIB and PTMO in different weight proportions as soft segment was synthesized using the two-step procedure according to the synthetic procedure exemplified in FIG. 2. BDO and MDI constituted the hard segment. The soft segment to hard segment ratio of 77:23 wt % was maintained.

For example, PIB_(sat)-PTMO-82-6 was synthesized as follows. HO-propyl-PIB-propyl-OH (M_(n)=2000, 5.3 g, 2.65 mmol), obtained by hydroboration oxidation of allyl telechelic PIB (Iván, B.; Kennedy, J. P. J. Polym. Sci., Part A: Polym. Chem. 1990, 28, 89), and PTMO (M_(n)=1000, 1.33 g, 1.33 mmol) were dried by azeotropic distillation from dry toluene (10 mL) solution. The mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to this mixture, followed by Sn(Oct)₂ (29.9 mg, 0.074 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (1.84 g, 7.36 mmol) was added to this mixture and the mixture was stirred vigorously for 30 min. BDO (308 mg, 3.38 mmol) was added to the resulting reaction mixture and the mixture was stirred for 4 hours at 100° C. The mixture was cooled to room temperature, poured in a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours.

The TPU exhibited the following characteristics: M_(n)=140000, PDI=2.2, UTS=20 MPa, elongation at break=550%, Young's modulus=6 MPa.

Example 10 Synthesis of Polyisobutylene (Saturated)/Polyether-Based Thermoplastic Urethane (PIB_(sat)-PTMO-TPU, 80A Shore Hardness)

TPU having mixtures of hydroxypropyl telechelic PIB and PTMO in different weight proportions as soft segment was synthesized using the two-step procedure according to the synthetic procedure exemplified in FIG. 2. BDO and MDI constituted the hard segment. The soft segment to hard segment ratio of 66:34 wt % was maintained in all the cases.

PIB_(sat)-PTMO-82-8 was synthesized as follows. HO-propyl-PIB-propyl-OH M_(n)=2000, 5.2 g, 2.6 mmol) and PTMO (M_(n)=1000, 1.3 g, 1.3 mmol) were dried by azeotropic distillation from dry toluene (10 mL) solution. The mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to this mixture, followed by Sn(Oct)₂ (42.5 mg, 0.105 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (2.64 g, 10.54 mmol) was added to the reaction mixture, and the mixture was stirred vigorously for 30 min. BDO (604 mg, 6.64 mmol) was added to the reaction mixture, and the mixture was stirred for 4 hours at 100° C. The mixture was cooled to room temperature, poured in a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours.

The TPU exhibited the following characteristics: M_(n)=85000, PDI=2.2, UTS=27 MPa, elongation at break=475%, Young's modulus=15 MPa.

Example 11 Synthesis of Polyisobutylene/Polyether-Based Thermoplastic Urethane (PIB-polyhexamethylene Oxide(PHMO)-TPU, 80A Shore Hardness)

TPU having mixtures of PIB and PHMO in different weight proportions as soft segment was synthesized using the two-step procedure according to the synthetic procedure exemplified in FIG. 2. BDO and MDI constituted the hard segment. The soft segment to hard segment ratio of 67:33 wt % was maintained.

For example, PIB-PHMO-82-8 was synthesized as follows. HO-Allyl-PIB-Allyl-OH (M_(n)=2200, 4.6 g, 2.1 mmol) and PHMO (M_(n)=920, 1.15 g, 1.25 mmol) were dried by azeotropic distillation from dry toluene (10 mL) solution. The mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to this mixture, followed by Sn(Oct)₂ (37.26 mg, 0.092 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (2.3 g, 9.22 mmol) was added to this mixture and the mixture was stirred vigorously for 30 min. BDO (534 mg, 5.87 mmol) was added to the resulting reaction mixture and the mixture was stirred for 4 hours at 100° C. The mixture was cooled to room temperature, poured in a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours.

The TPU exhibited the following characteristics: M_(n)=73000, PDI=3.4, UTS=18 MPa, elongation at break=280%, Young's modulus=27 MPa.

Example 12 Synthesis of Polyisobutylene (Saturated)/Polyether-Based Thermoplastic Urethane (PIB_(sat)-PHMO-TPU, 60A Shore Hardness)

TPU having mixtures of hydroxypropyl telechelic PIB and PHMO in different weight proportions as soft segment was synthesized using the two-step procedure according to the synthetic procedure exemplified in FIG. 2. BDO and MDI constituted the hard segment. The soft segment to hard segment ratio of 76:24 wt % was maintained in all the cases.

For example, PIB_(sat)-PHMO-82-6 was synthesized as follows. HO-propyl-PIB-propyl-OH (M_(n)=2000, 4.6 g, 2.3 mmol) and PHMO (M_(n)=920, 1.15 g, 1.25 mmol) were dried by azeotropic distillation from dry toluene (10 mL) solution. The mixture was kept at 45° C. for 3 hours under vacuum. 25 mL of dry toluene was added to this mixture, followed by Sn(Oct)₂ (26.3 mg, 0.065 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. MDI (1.62 g, 6.48 mmol) was added to this mixture and the mixture was stirred vigorously for 30 min. BDO (267 mg, 2.93 mmol) was added to the resulting reaction mixture and the mixture was stirred for 4 hours at 100° C. The mixture was cooled to room temperature, poured in a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours.

The TPU exhibited the following characteristics: M_(n)=120000, PDI=3.4, UTS=16 MPa, elongation at break=550%, Young's modulus=6 MPa.

Example 13 Synthesis of Polyisobutylene (Saturated)/Polyether-Based Thermoplastic Urethane (PIB_(sat)-PTMO-TPU, 95A Shore Hardness) Without Catalyst

TPU having mixtures of hydroxypropyl telechelic PIB and PTMO-diol in different weight proportions as soft segment was synthesized using the two-step procedure according to the synthetic procedure exemplified in FIG. 2. BDO and MDI constituted the hard segment. The ration of soft segment to hard segment of 60:40 wt % was maintained in all the cases.

For example, PIB_(sat)-PTMO-82-9 was synthesized as follows. HO-propyl-PIB-propyl-OH (M_(n)=2000, 2.8 g, 1.4 mmol) and PTMO (M_(n)=1000, 0.8 g, 0.8 mmol) were dried by azeotropic distillation from dry toluene (10 mL) solution. The mixture was kept at 45° C. for 3 hours under vacuum and 25 mL of dry toluene was added to this mixture. The temperature of the mixture was raised to 100° C. under a slow stream of dry nitrogen gas. MDI (1.92 g, 7.7 mmol) was added to this mixture and the mixture was stirred vigorously for 1 h and 30 min. BDO (500 mg, 5.5 mmol) was added to the resulting reaction mixture and the mixture was stirred for 4 hours at 100° C. The mixture was cooled to room temperature, poured in a Teflon mold and the solvent was evaporated at room temperature in air for 48 hours. Finally the polymer was dried under vacuum at 50° C. for 12 hours.

The TPU exhibited the following characteristics: M_(n)=88000, PDI=3.7.

Example 14 Long Term In Vitro Biostability of Segmented Polyisobutylene-Based Thermoplastic Polyurethanes

Long term in vitro biostability of termoplastic polyurethanes (TPUs) containing mixed polyisobutylene (PIB)/poly(tetramethylene oxide) (PTMO) soft segment was studied under accelerated conditions in 20% H₂O₂ solution containing 0.1M CoCl₂ at 50° C. to predict resistance to metal ion oxidative degradation in vivo. The PIB-based TPUs containing PTMO showed significant oxidative stability as compared to the commercial controls such as Pellethane™ 2686-55D and 2686-80A. After 12 weeks in vitro (equivalent of approximately 10 years in vivo) the PIB-PTMO TPUs with 10-20% PTMO in the soft segment showed 6-15% weight loss whereas the Pellethanes™ degraded completely in about 9 weeks. The weight loss was linearly proportional to the PTMO content in the PIB-PTMO TPUs. ATR-FTIR spectroscopy confirmed the degradation of Pellethanes™™ via MIO by the consistent loss of the approximately 1110 cm⁻¹ aliphatic C—O—C stretching peak height attributed to chain scission, and the appearance of a new peak approximately 1174 cm⁻¹ attributed crosslinking. No such absorption bands were apparent in the spectra of the PIB-based TPUs. The PIB-based TPUs exhibited 10-30% drop in tensile strength compared to 100% for the Pellethanes™ after 12 weeks. The drop in tensile strength correlated approximately with PTMO content in the TPU. Molecular weight results correlated well with tensile strength, showing a slight decrease 10-15% at 12 weeks. The Pellethanes™ showed a dramatic decrease in Mn as well as an increase in low molecular weight degradation product. SEM showed severe cracking in the Pellethanes™ after two weeks, whereas the PIB-based TPUs exhibited a continuous surface morphology. The weight loss, tensile, and SEM data correlate well with each other and indicate excellent biostability of these materials.

Materials and Methods

Polyurethanes

Control samples consisted of Pellethane™ 2363-55D and Pellethane™ 2363-80A. Polyurethanes of varying hardness and PIB:PTMO compositions were synthesized as reported previously and are listed in Table 24. The two-stage process is described for a representative TPU (60A 82) as follows: HO-Allyl-PIB-Allyl-OH (Mn=2200 g/mol, 5.2 g, 2.36 mmol) and PTMO (Mn=1000 g/mol, 1.3 g, 1.3 mmol) were dried by azeotropic distillation using dry toluene (10 mL). The mixture was kept at 45° C. for 3 hours under vacuum. To it 25 mL of dry toluene was added followed by Sn(Oct)₂ (28.3 mg, 0.07 mmol) in toluene. The mixture was heated at 80° C. under a slow stream of dry nitrogen gas. To it MDI (1.76 g, 7.02 mmol) was added and the mixture was stirred vigorously for 30 min. To it BDO (302 mg, 3.36 mmol) was added and the mixture was stirred at 100° C. for 4 hours. The mixture was cooled to room temperature, poured into a Teflon® mold and the solvent was evaporated at room temperature in air for 48 hours. Finally, the polymer was dried under vacuum at 50° C. for 12 hours. A PIB TPU without PTMO was prepared similarly. The saturated PIB-PTMO polyurethane was synthesized using HO-propyl-PIB-propyl-OH, prepared using a method developed by Kennedy (Iván, B.; Kennedy, J. P. J. Polym. Sci., Part A: Polym. Chem. 1990, 28, 89). The polyurethanes were characterized prior to accelerated degradation using 1H NMR and GPC. The harder compositions (80A 91, 100A) did not dissolve in the GPC eluent.

TABLE 24 PIB and PTMO wt % HO- PTMO HO-PIB-OH^(a) PTMO-OH^(b) SS:HS wt % Shore A Code (wt % in SS) (wt % in SS) (wt:wt) in TPU hardness P55D 0 100 60:40 60 100 P80A 0 100 65:35 65 80 60A 82 80 20 79:21 16 60 60A 91 90 10 79:21 8 60 80A 73 70 30 65:35 19.5 80 80A 82 80 20 65:35 13 80 80A 91 90 10 65:35 6.5 80 100A 82 80 20 60:40 12 100 PIB 60A 100 0 79:21 0 60 SAT 60A 90 10 79:21 8 60 91 ^(a)HO-PIB-OH, Mn = 2200 g/mol. ^(b)HO-PTMO-OH, Mn = 1000 g/mol The polyurethanes were compression molded using a Carver Laboratory Press model C at a load of 16,000 lbs. at 160° C. They were molded into thin films ranging in thickness from 0.2 mm-0.5 mm and cut into rectangular strips with approximate dimensions of 3 mm in width and 30 mm in length. In Vitro Accelerated Degradation

The samples were placed in vials and soaked in a 20% H₂O₂ in aqueous 0.1 M CoCl₂ solution and stored at 50° C. The solutions were changed every other day to ensure a steady concentration of radicals. At time points after 1, 2, 4, 6, and 12 weeks, dedicated samples were removed from the oxidative environment, washed 7 times in aqueous 1% Triton X-100 surfactant solution, 5 times in ethanol, and 5 times in distilled water and dried under vacuum at 80° C. until constant weight.

Characterization

Dry samples were characterized by weight loss, ATR-FTIR, ultimate tensile strength, elongation at break, SEM, and GPC. Each data point consisted of three identical samples. Of the quantitative data, the reported value is an average of the three samples.

ATR-FTIR

ATR-FTIR was performed on a Thermo Electron Corporation Nicolet 4700 FT-IR with a Thermo Electron Corporation Smart Orbit attachment for ATR with a diamond crystal. Thirty-two scans were averaged to obtain one representative spectrum for each sample. The respective dry clean TPU strip was placed on the crystal, firmly secured using the foot attachment, and scanned for analysis. The region of interest was between approximately 1700 cm⁻¹ and 1100 cm⁻¹, which includes HS degradation product (approximately 1650 cm⁻¹), SS degradation moiety (approximately 1110 cm⁻¹) and product (approximately 1170 cm⁻¹) and the normalized reference peak (approximately 1410 cm⁻¹).

Weight Loss

Weights were measured of dry polyurethane films before and after oxidative treatment on a Sartorius MC1 Analytic AC 210S balance.

Mechanical Testing

Tensile testing was performed at room temperature and atmospheric conditions with a 50 lb. load cell on an Instron Model Tensile Tester 4400R at 50 mm/min extension rate until failure. Ultimate tensile strength and elongation at break were recorded.

GPC Analysis

Molecular weights and molecular weight distributions were measured with a Waters HPLC system equipped with a model 510 HPLC pump, model 410 differential refractometer, model 441 absorbance detector, online multiangle laser light scattering (MALLS) detector (MiniDawn, Wyatt Technology Inc.), Model 712 sample processor, and five Ultrastyragel GPC columns connected in the following series: 500, 10³, 10⁴, 10⁵, and 100 Å. THF:TBAB (98:2, wt:wt) was used as a carrier solvent with a flow rate of 1 mL/min.

Scanning Electron Microscopy

Portions of the dry treated films were isolated for SEM analysis. Surface morphology was observed on gold sputter coated samples using a Denton Vacuum Desk IV Cold Cathode Sputter Coater. The samples were sputter coated for 1.5 min at 25% power, corresponding to a thickness of approximately 15A of gold. The coated samples were observed using a JEOL model JSM 7401F field emission scanning electron microscope. Several representative pictures were taken at 30× and 300× magnification.

3. Results and Discussion

ATR-FTIR

ATR-FTIR analysis was performed to confirm the presence and progression of the MIO mechanism as put forth by Schubert and coworkers. According to their suggested mechanism, a hydroxyl radical may abstract an α-hydrogen from the polyether segment. The resulting radical may combine with another chain radical to form a crosslink junction or react with another hydroxyl radical to form a hemiacetal. The hemiacetal oxidizes to ester which is subsequently acid hydrolyzed resulting in chain scission. Therefore progression of degradation can be observed by following the disappearance of the SS ether peak and/or the appearance of the crosslinking peak. All spectra were normalized to the peak at 1410 cm⁻¹, which corresponds to the aromatic C—C stretch of the hard segment.

The PIB-PTMO polyurethanes all show very small changes in the FTIR spectrum. A representative spectrum, that of 60A 82, is shown in FIG. 6.

As can be seen, There is no appreciable change in the aliphatic ether C—O—C absorbance at 1110 cm⁻¹ and C—O—C branching absorbance at approximately 1174 cm⁻¹ is absent. However, an increase in the aliphatic absorbances with time is observed (aliphatic CH₂ bending at 1470 cm⁻¹, PIB dimethyl wag at 1388 cm⁻¹, and aliphatic α-CH₂ wag at 1365 cm⁻¹). This behavior can be rationalized by migration of PIB segments to the surface during vacuum drying at 80° C. In these PIB-PTMO TPUs cross-linking may be absent since there is not a significant presence or mobility of PTMO to allow two polymer radicals to combine before they are otherwise cleaved. Similar results are observed in the other PIB-PTMO TPU spectra. The Sat 60A 91 batch was included in this study to determine if the unsaturated allyl moiety in the PIB diol was vulnerable to oxidation. The FTIR spectrum of the TPU using the saturated diol appears identical to that of the TPU containing unsaturated diol. Additionally the PIB 60A TPU was included to confirm that there is only polyether SS degradation, and not HS degradation in these TPUs. This hypothesis was confirmed as the spectrum shows no change at all. There is no change in the PIB absorbance at 1388 cm⁻¹ or ether absorbance at 1111 cm⁻¹ since there is no polyether to be degraded. There is also no evidence of HS degradation. In Table 25 are listed the IR absorbances where trends of change were observed.

TABLE 25 Assigned ATR-FTIR Spectral Peak Changes Wave number (cm−1) Proposed peak assignment P80A P55D PIB-PTMO 1637 NH2 aromatic amine X 1476 Aliphatic CH2 bend X 1388 PIB CH3 wag X 1365 Aliphatic α-CH2 wag X X X 1173 C-O-C branching X X 1110 Aliphatic C-O-C X X

The Pellethane™ samples showed the expected behavior as is consistent with previous studies. The spectra of P55D are shown in FIG. 7.

The spectrum shows a significant decrease in aliphatic C—O—C absorption at 1109 cm⁻¹ after 1 week, then more slowly until 6 weeks. Concurrently, we observe a rapid disappearance of the aliphatic α-CH₂ absorbance at 1364 cm⁻¹ after just one week. Also the C—O—C branching absorbance at 1172 cm⁻¹ is observed immediately at 1 week, then stays constant in magnitude. As it will be seen later, the Pellethanes™ continued to degrade at a constant, if not accelerated rate after 1 week, and so an explanation is in order for the IR spectra. ATR-FTIR is a surface characterization technique and degradation is expected to begin at the surface. Therefore we conclude that the segments vulnerable at the surface are oxidized almost immediately and deeper oxidation occurs in the following weeks as observed from the rest of the analyses.

Weight Loss

The weight loss plotted against time is shown in FIG. 8. The PIB-PTMO TPUs all show very low weight loss after 12 weeks ranging from values of 6-15% depending on the composition. Among the 60A batch, the 90/10 composition showed lower weight loss of 6% compared to 8% for the 80/20 composition. The Sat 60A 91 shows weight loss comparable to the unsaturated 60A 91. Similarly in the 80A batch, the TPUs with lower PTMO content showed lower weight loss, from 15, 10 and 6% for 30, 20, and 10% PTMO respectively. More specifically, the weight loss could be correlated to the PTMO content in the polyurethanes. In FIG. 9 weight loss at 12 weeks vs. PTMO content is plotted.

As can be seen for the PIB-PTMO TPUs there is approximately a linear relationship between the weight loss and the PTMO content. This discovery supports the notion that it is the polyether SS which degrades via MIO and it is these portions which are excised from the polyurethane. Interestingly, 60A 82 showed a lower weight loss than expected for its PTMO content. The TPU which contained only PIB also showed a small weight loss, which fits the plot. Since there is such a large surface area to volume ratio, we expect to see some small erosion from the surface. The Pellethane™ control samples showed noticeable weight loss even after 1 week in vitro, and P80A and P55D completely degraded after approximately 7 and 9 weeks, respectively. These findings are consistent with previous findings concerning such polyether based TPUs.

Mechanical Properties

Tensile strength is plotted as a percentage of the original untreated sample vs. time in FIG. 10.

A drastic difference in the plots for P55D versus the PIB-PTMO TPUs can be seen. In the PIB-PTMO TPUs a minimal decrease in tensile strength is observed for all samples, although the rate of tensile loss varies for the different samples. The PIB-PTMO TPUs show differing losses which are roughly correlated to the PTMO content. Among the 60A batch, the tensile losses from the different compositions are comparable. The 12 weeks data point for the 60A 91 could not be obtained because of a poor sample set. Nevertheless, the trend observed up to 6 weeks follows very closely that of the Sat 60A 91. Minimal decrease in tensile strength was also observed in the 60A PIB sample, which showed no degradation as evident from weight loss and FTIR studies. This indicates that 1-2 MPa may be within experimental error with the load cell and instrument used. Among the 80A batch the 80/20 composition shows ˜21% drop in tensile strength, whereas the 90/10 composition shows only a decrease of ˜13%. The 80A 73 sample (not shown) showed an initial increase in tensile strength, then subsequently a slower decrease. This is attributed to be due to crosslinking initially, followed by chain scission consistent with the increased amount of PTMO in this sample. At this amount of PTMO (19.5% of total TPU), there are sufficient concentration of chain radicals such that crosslinking is able to occur as well as chain scission. Although the % tensile strength at 12 weeks is greater than the other PIB-PTMO TPUs, extrapolation of the data would predict that the tensile strength 80A 73 would drop more sharply at longer time intervals.

P55D shows greater resistance to degradation compared to P80A due to more crystallinity. Thus the 100 A 82 composition is expected to have comparable if not better strength than the 80A 82 composition, yet we see greater tensile drop. This may suggest that PIB is a better protector of the surface than the hard segment. Some of the samples actually show inhibition periods wherein the tensile strength does not begin to decrease until 2, 4, or even 6 weeks (esp. 80A 82). The ultimate elongation of the PIB-PTMO TPUs did not change significantly over the course of the treatment. The Pellethanes™ again showed expected of MIO behavior. P55D showed gradual tensile loss over time up to 6 weeks, and at 12 weeks there was no sample to test. P80A (not shown) showed an initial increase in tensile strength after one week, then a gradual decrease.

This is explained by crosslinking of the chains initially, with chain scission occurring afterward as was observed with 80A 73.

GPC Analysis

The TPU samples were dissolved in the carrier solvent of THF:TBAB (98:2, wt:wt). However, some of the harder compositions could not be dissolved. Representative GPC RI traces are shown FIG. 11 for Sat 60A91. The TBAB elutes beyond 47 minutes.

The loss in molecular weight is minimal in agreement with the weight loss and tensile data. Mn decreases slightly from 130,000 g/mol to 112,000 g/mol after 6 weeks, then negligibly to 110,000 g/mol at 12 weeks while the PDI remained unchanged at 1.6. These data are in agreement with the FTIR and tensile data.

In FIG. 12 the refractive index traces of P80A are shown. The number average molecular weight shows a clear trend decreasing from 84,000 g/mol before treatment to 18,000 g/mol at 4 weeks and 14,000 g/mol at 6 weeks. There is a clearly visible rise in some low molecular weight degradation product(s) by 4 weeks. Simultaneously there is an increase in the molecular weight distribution. These findings are in agreement with the ATR-FTIR, weight loss, and tensile results. P55D shows similar behavior with decreasing Mn and increasing PDI.

SEM

Representative SEM pictures taken at 300× magnification are shown in FIGS. 13-16. Shown in FIG. 13 is P55D which shows the often observed behavior of “mud cracking” with treatment time. The surface density of cracks increases with time, and the visual inspection affirms the previous data as well.

In FIG. 14, FIG. 15 and FIG. 16, scanning electron micrographs of the 80A series are shown to depict the effect of PTMO content on the surface morphology. The responses of these TPUs to degradation are certainly different than the Pellethanes™, but a trend of increasing surface imperfections with increasing PTMO content can be seen. The 80A 73 shows some small holes as well as surface roughening after 12 weeks. 80A 82 shows somewhat larger craters after 12 weeks, and 80A 91 shows essentially no change in the surface morphology after 12 weeks. Some small holes are often observed in various samples, but these are not expected to be due to degradation. The same patterns were observed in the 60A PIB samples, which did not degrade; therefore such holes are expected to be an artifact of the compression molding process.

The 60A series show analogous morphologies, with the 90/10 composition showing a less flawed surface. The 100A 82 composition shows morphology comparable to 80A91.

Conclusion

After 12 weeks in vitro, which correlates to approximately 10 years in vivo, the thermoplastic polyurethanes of the present invention showed minimal degradation and minimal decrease in performance. Using unsaturated PIB diol rather than saturated PIB diol did not have an effect on the degradation of the thermoplastic polyurethanes of the invention. The PIB segment and the hard segment were not observed to degrade. Increasing the amount of polyether diol incorporated in the thermoplastic polyurethanes of the invention increased the degradation rate, suggesting a degradation mechanism identical to that postulated before for PTMO-based thermoplastic polyurethanes. Therefore, a low PTMO content was considered to be desirable to ensure biostability.

Equivalents

While this invention has been particularly shown and described with references to example embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. 

What is claimed is:
 1. An elastomeric polymer, consisting of: (1) a hard segment in the amount of 32% to 36% by weight of the elastomeric polymer, wherein the hard segment consists of: a urethane, urea or urethane urea; optionally at least one chain extender; and optionally at least one diisocyanate residue; and (2) a soft segment in the amount of 64% to 68% by weight of the elastomeric polymer, wherein the soft segment consists of: (a) about 10% to about 30% by weight of the soft segment of a combination of at least one polyether macrodiol and at least one polycarbonate macrodiol; and (b) about 70% to about 90% by weight of the soft segment of at least one polyisobutylene macrodiol and/or diamine; wherein the number average molecular weight of the elastomeric polymer is not less than 40 kilodaltons, and wherein the at least one polyether macrodiol is selected from the group consisting of poly(propylene oxide) diol, poly(trimethylene oxide) diol, poly(tetramethylene oxide) diol, poly(hexamethylene oxide) diol, poly(heptamethylene oxide) diol, poly(octamethylene oxide) diol and poly(decamethylene oxide) diol.
 2. The elastomeric polymer of claim 1, wherein the number average molecular weight of the elastomeric polymer is not less than 50 kilodaltons.
 3. The elastomeric polymer of claim 1, wherein the at least one polyisobutylene macrodiol or diamine is of formula:

wherein: each X is independently —OH, —NH₂ or —NHR₄; R_(l) is an initiator residue; R₂ and R₃ and R₄ is each independently a C1—C16 alkyl, a C3—C16 cycloalkyl, a C2—C16 alkenyl, a C3—C16 cycloalkenyl, or a C6—C18 aryl, wherein, for each occurrence, R₂ or R₃ is, independently, optionally substituted with one or more groups selected from halo, cyano, nitro, dialkylamino, trialkylamino, C1—C16 alkoxy and C1—C16 haloalkyl; and n and m are each, independently, integers from 1 to
 500. 4. The elastomeric polymer of claim 1, wherein the polyisobutylene macrodiol is hydroxyallyl telechelic polyisobutylene.
 5. The elastomeric polymer of claim 1, wherein the polyisobutylene macrodiol is hydroxyalkyl telechelic polyisobutylene.
 6. The elastomeric polymer of claim 5, wherein the polyisobutylene macrodiol is hydroxypropyl telechelic polyisobutylene.
 7. The elastomeric polymer of claim 1, wherein the polyisobutylene diamine is aminoallyl telechelic polyisobutylene.
 8. The elastomeric polymer of claim 1, wherein the number average molecular weight of the at least one polyisobutylene macrodiol is about 400 Da to about 6000 Da.
 9. The elastomeric polymer of claim 1, wherein the number average molecular weight of the at least one polyisobutylene macrodiol is about 1000 Da to about 3000 Da.
 10. The elastomeric polymer of claim 1, wherein the at least one polycarbonate macrodiol includes at least one poly(alkylene carbonate).
 11. The elastomeric polymer of claim 1, wherein the hard segment comprises a diisocyanate residue and a chain extender.
 12. The elastomeric polymer of claim 11 wherein the diisocyanate includes at least one member selected from the group consisting of 4,4′-methylenephenyl diisocyanate; methylene diisocyanate; p-phenylene diisocyanate; cis-cyclohexane-1,4-diisocyanate; trans-cyclohexane-1,4-diisocyanate; a mixture of cis cis-cyclohexane-1,4-diisocyanate and trans-cyclohexane-1,4-diisocyanate; 1,6-hexamethylene diisocyanate; 2,4-toluene diisocyanate; cis-2,4-toluene diisocyanate; trans-2,4-toluene diisocyanate; a mixture of cis-2,4-toluene diisocyanate and trans-2,4-toluene diisocyanate; p-tetramethylxylene diisocyanate; and m-tetramethylxylene diisocyanate.
 13. The elastomeric polymer of claim 11, wherein the chain extender includes at least one member selected from the group consisting of 1,4-butanediol; 1,5 pentanediol; 1,6-hexanediol; 1,8-octanediol; 1,9-nonanediol; 1,10-decanediol, 1,12-dodacanediol; 1,4-cyclohexane dimethanol; p-xyleneglycol and 1,4-bis(2-hydroxyethoxy)benzene.
 14. The elastomeric polymer of claim 11, wherein the chain extender includes at least one member selected from the group consisting of 1,4-diaminobutane; 1,5-diaminopentane; 1,6-diaminohexane; 1,8-diaminooctane; 1,9-diaminononane; 1,10-diamonodecane, 1,12-diaminododacane; 1,4-diaminocyclohexane; 2,5-diaminoxylene and isophoronediamine and water.
 15. The elastomeric polymer of claim 11, wherein the diisocyanate is 4,4′-methylenephenyl diisocyanate and wherein the chain extender is 1,4-butanediol.
 16. The elastomeric polymer of claim 1, wherein: the polyisobutylene macrodiol of the soft segment comprises a hydroxylalkyl telechelic polyisobutylene residue, and the hard segment comprises a 4,4′-methylenediphenyl diisocyanate and 1,4-butanediol chain extender.
 17. The elastomeric polymer of claim 1, wherein: the polyisobutylene macrodiol of the soft segment comprises a hydroxylalkyl telechelic polyisobutylene residue, a poly (alkylene carbonate) residue, and a poly(tetramethylene oxide) diol residue; and the hard segment comprises a 4,4′-methylenediphenyl diisocyanate and 1,4-butanediol chain extender.
 18. The elastomeric polymer of claim 1, wherein: the polyisobutylene macrodiol of the soft segment comprises a hydroxylalkyl telechelic polyisobutylene residue, a poly (alkylene carbonate) residue, and a poly(hexamethylene oxide) diol residue; the hard segment comprises a 4,4′-methylenediphenyl diisocyanate and 1,4-butanediol chain extender.
 19. The elastomeric polymer of claim 1, wherein the polyisobutylene macrodiol of the soft segment comprises (a) a hydroxyallyl difunctional polyisobutylene residue; (b) a poly (alkylene carbonate) residue; and (c) a poly(tetramethylene oxide) diol or poly(hexamethylene oxide) diol residue; and the hard segment comprises (d) a 4,4′-methylenediphenyl diisocyanate; and (e) 1,4-butanediol chain extender.
 20. The polyurethane elastomeric polymer of claim 1, wherein the soft segment includes from about 10% to about 20% by weight of the soft segment of the at least one polycarbonate.
 21. The elastomeric polymer of claim 1, wherein the soft segment includes from about 10% to about 20% by weight of the soft segment of the at least one polyether and the at least one polycarbonate.
 22. The elastomeric polymer of claim 1, wherein the soft segment includes from about 10% to about 20% by weight of the soft segment of at least one polyether.
 23. An article of manufacture, comprising: an elastomeric polymer, said elastomeric polymer, consisting of: (1) a hard segment in the amount of 10% to 60% by weight of the elastomeric polymer, wherein the hard segment consists of: a urethane, urea or urethane urea; optionally at least one chain extender; and optionally at least one diisocyanate residue; and (2) a soft segment in the amount of 40% to 90% by weight of the elastomeric polymer, wherein the soft segment consists of: (a) about 10% to about 30% by weight of the soft segment of a combination of at least one polyether macrodiol and at least one polycarbonate macrodiol; (b) about 70% to about 90% by weight of the soft segment of at least one polyisobutylene macrodiol and/or diamine; and (c), wherein the number average molecular weight of the elastomeric polymer is not less than 40 kilodaltons, and wherein the article of manufacture is a medical device or an implant, and wherein the at least one polyether macrodiol is selected from the group consisting of poly(propylene oxide) diol, poly(trimethylene oxide) diol, poly(tetramethylene oxide) diol, poly(hexamethylene oxide) diol, poly(heptamethylene oxide) diol, poly(octamethylene oxide) diol and poly(decamethylene oxide) diol.
 24. The article of claim 23, wherein the number average molecular weight of the elastomeric polymer is not less than 50 kilodaltons.
 25. The article of claim 23, wherein the medical device or implant is a fiber, film, engineering plastic, fabric, coating, and adhesive joint.
 26. The article of claim 23, wherein the medical device or implant is a cardiac pacemaker, a defibrillator, a catheter, an implantable prosthesis, a cardiac assist device, an artificial organ, a pacemaker lead, a defibrillator lead, a blood pump, a balloon pump, an a-V shunt, a biosensor, a membrane for cell encapsulation, a drug delivery device, a wound dressing, an artificial joint, an orthopedic implant or a soft tissue replacement.
 27. A process for preparing an elastomeric polymer, comprising the steps of: a) forming a mixture that includes at least one polyisobutylene macrodiol and/or diamine, at least one polyether macrodiol and a chain extender; and b) reacting the mixture with a diisocyanate to yield an elastomeric polymer, wherein the elastomeric polymer consists of: (i) a hard segment in the amount of 32% to 36% by weight of the elastomeric polymer, wherein the hard segment includes a urethane, urea or urethaneurea; (ii) a soft segment in the amount of 64% to 68% by weight of the elastomeric polymer, wherein the soft segment consists of: at least 2% by weight of the soft segment of at least one polyether macrodiol, and at least one polycarbonate macrodiol, and at least 2% by weight of the soft segment of the at least one polyisobutylene macrodiol and/or diamine, wherein the number average molecular weight of the elastomeric polymer is not less than 40 kilodaltons, and wherein the at least one polyether macrodiol is selected from the group consisting of poly(propylene oxide) diol, poly(trimethylene oxide) diol, poly(tetramethylene oxide) diol, poly(hexamethylene oxide) diol, poly(heptamethylene oxide) diol, poly(octamethylene oxide) diol and poly(decamethylene oxide) diol; and (iii) optionally a catalyst.
 28. The article of claim 27, wherein the number average molecular weight of the elastomeric polymer is not less than 50 kilodaltons.
 29. The process of claim 27, wherein the at least one polyisobutylene macrodiol or diamine of the soft segment is of the formula:

wherein: each X is —OH, —NH₂ or —NHR₄; R₁ is an initiator residue; R₂ and R₃ and R₄ is each independently a C1—C16 alkyl, a C3—C16 cycloalkyl, a C2—C16 alkenyl, a C3—C16 cycloalkenyl, or a C2—C16 alkynyl, a C3—C16 cycloalkynyl, or a C6—C18 aryl, wherein, for each occurrence, R₂ or R₃ is, independently, optionally substituted with one or more groups selected from halo, cyano, nitro, dialkylamino, trialkylamino, C1—C16 alkoxy and C1—C16 haloalkyl; and n and m are each independently integers from 1 to
 500. 30. The process of claim 27 wherein mixture is formed at a temperature of about 45° C. to about 120° C.
 31. The process of claim 27 wherein the mixture is formed in the presence of a catalyst.
 32. The process of claim 31 wherein the catalyst is stannous octoate.
 33. A process for preparing an elastomeric polymer, comprising the steps of: a) reacting a diisocyanate with a mixture that includes at least one polyisobutylene macrodiol and/or diamine, at least one polycarbonate macrodiol, and at least one polyether macrodiol to form a prepolymer having terminally reactive diisocyanate groups; and b) reacting the prepolymer with a chain extender to yield an elastomeric polymer, wherein the elastomeric polymer consists of: (i) a hard segment in the amount of 32% to 36% by weight of the elastomeric polymer, wherein the hard segment includes a urethane, urea or urethaneurea; and (ii) a soft segment in the amount of 64% to 68% by weight of the elastomeric polymer, wherein the soft segment consists of: at least 2% by weight of the soft segment of the at least one polyether macrodiol, and the at least one polycarbonate macrodiol and at least 2% by weight of the soft segment of the at least one polyisobutylene macrodiol and/or diamine, wherein the number average molecular weight of the elastomeric polymer is not less than 40 kilodaltons, and wherein the at least one polyether macrodiol is selected from the group consisting of poly(propylene oxide) diol, poly(trimethylene oxide) diol, poly(tetramethylene oxide) diol, poly(hexamethylene oxide) diol, poly(heptamethylene oxide) diol, poly(octamethylene oxide) diol and poly(decamethylene oxide) diol.
 34. The process of claim 33, wherein the number average molecular weight of the elastomeric polymer is not less than 50 kilodaltons.
 35. The process of claim 33, wherein the at least one polyisobutylene macrodiol or diamine of the soft segment is of the formula:

wherein: each X is —OH, —NH₂ or —NHR₄; R_(l) is an initiator residue; R₂ and R₃ and R₄ is each independently a C1—C16 alkyl, a C3—C16 cycloalkyl, a C2—C16 alkenyl, a C3—C16 cycloalkenyl, or a C2—C16 alkynyl, a C3—C16 cycloalkynyl, or a C6—C18 aryl, wherein, for each occurrence, R₂ or R₃ is, independently, optionally substituted with one or more groups selected from halo, cyano, nitro, dialkylamino, trialkylamino, C1—C16 alkoxy and C1—C16 haloalkyl; and n and m are each independently integers from 1 to
 500. 36. The process of claim 33 wherein the at least one polycarbonate macrodiol includes at least one poly(alkylene carbonate).
 37. The process of claim 33 wherein the chain extender includes at least one member of the group consisting of 1,4-butanediol; 1,5-pentanediol; 1,6-hexanediol; 1,8-octanediol; 1,9-nonanediol; 1,10-decanediol, 1,12-dodecanediol; 1,4-cyclohexane dimethanol; p-xyleneglycol and 1,4-bis(2-hydroxyethoxy) benzene.
 38. The process of claim 33 wherein the chain extender includes at least one member of the group consisting of 1,4-diaminobutane; 1,5-diaminopentane; 1,6-diaminohexane; 1,8-diaminooctane; 1,9-diaminononane; 1,10-diamonodecane, 1,12-diaminododacane; 1,4-diaminocyclohexane; 2,5-diaminoxylene and isophoronediamine and water.
 39. A pacemaker lead comprising a polymer, the polymer consisting of: (1) a hard segment in the amount of 32% to 36% by weight of the elastomeric polymer, wherein the hard segment includes a urethane, urea or urethane urea; and (2) a soft segment in the amount of 64% to 68% by weight of the elastomeric polymer, wherein the soft segment consists of: (a) from 10% to 30% by weight of the soft segment of a combination of at least one poly(tetramethylene oxide) diol and at least one polycarbonate macrodiol; and (b) from 70% to 90% by weight of the soft segment of at least one polyisobutylene macrodiol.
 40. The pacemaker lead of claim 39 wherein the polymer has a Shore hardness of from 60A to 100A. 